US20050258928A1 - Code-shaped temperature fuse and sheet-shaped temperature fuse - Google Patents
Code-shaped temperature fuse and sheet-shaped temperature fuse Download PDFInfo
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- US20050258928A1 US20050258928A1 US10/526,980 US52698005A US2005258928A1 US 20050258928 A1 US20050258928 A1 US 20050258928A1 US 52698005 A US52698005 A US 52698005A US 2005258928 A1 US2005258928 A1 US 2005258928A1
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Images
Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
- H01H37/00—Thermally-actuated switches
- H01H37/74—Switches in which only the opening movement or only the closing movement of a contact is effected by heating or cooling
Definitions
- the present invention relates to a code type thermal fuse and a sheet type thermal fuse, which can be disconnected when any part thereof is exposed in an abnormal high temperature state, so that the abnormal temperature can be detected. More particularly, the present invention relates to the code type thermal fuse and the sheet type thermal fuse, of which disconnection time is still good even after being deteriorated due to aging by heat, and which has good operative reliability.
- a code type thermal fuse comprising a space layer and an insulating cover layer around a center core member, on which a conductor meltable at a predetermined temperature is wound in the lateral direction on an elastic core.
- a code type thermal fuse wherein a core wire, comprising a metal wire meltable at a predetermined temperature, is wound in the lateral direction with predetermined intervals on a core member and is inserted into a protection tube.
- the protection tube comprises a glass braid sleeve covered by an extruded silicone rubber.
- a code type thermal fuse comprising: a fuse core produced by winding a conductor meltable at a predetermined temperature on an insulating core member continuously provided in the length direction and an insulating cover covering the outer periphery of the fuse core, characterized in that: the conductor can be cut by expanding the insulating core member at a predetermined temperature and/or by contracting the insulating cover at the predetermined temperature.
- code type thermal fuse as claimed in claim 1 , further characterized in that: the insulating core member has at least one or more protrusions formed continuously or intermittently in the length direction on the outer periphery of the insulating core member.
- the code type thermal fuse as claimed in claim 1 or claim 2 , further characterized in that: the insulating cover has at least one or more protrusions formed continuously or intermittently in the length direction on the inner periphery of the insulating cover.
- the code type thermal fuse as claimed in claim 1 , further characterized in that: another line-shaped or braid-shaped insulator is provided on the inner peripheral side of the insulating cover; and the conductor is sandwiched between the insulating core member and the line-shaped or braid-shaped insulator at least partially in the length direction of the conductor.
- the code type thermal fuse as claimed in claim 4 further characterized in that: the line-shaped or braid-shaped insulator has a characteristic of contracting in the length direction around the melting temperature of the conductor.
- the code type thermal fuse as claimed in claim 4 further characterized in that: the line-shaped or braid-shaped insulator has a characteristic of expanding in the peripheral direction around a melting temperature of the conductor.
- the code type thermal fuse as claimed in any one claim of claim 1 through claim 6 , further characterized in that: the insulating core member comprises a gas-containing material as a structural element.
- the code type thermal fuse as claimed in claim 7 further characterized in that: the insulating core member comprises a gas-containing material covering a periphery of a tensile resistant member at the center of the insulating core member.
- a sheet type thermal fuse comprising: the code type thermal fuse according to any one claim of claim 1 through claim 8 , provided on a flat surface in a serpentine manner; and means for fixing a layout of the code type thermal fuse.
- the code type thermal fuse which is surely disconnected at abnormal high temperature even at any position to which any compression force is not applied, and after disconnection, which has no risk of re-contact by melted conductor, etc., whereby any inappropriate operation is prevented. Further, it is also possible to obtain the sheet type thermal fuse substantially having the same characteristic as that of the code type thermal fuse as mentioned above.
- the thermal fuse of the present invention may further serve, not only for prevention of deterioration of operative reliability due to lost of flux function under practical using conditions, but also for improvement of operative reliability of aged code type thermal fuse, against such as formation of surface oxide film due to thermal oxidization of conductor.
- thermal fuse of the present invention is useful, because there is substantially no change of the structure of such a thermal fuse as compared with that of conventional thermal fuses assembly, it is also possible to use widely as a safety device for various heat apparatus, by not increasing the production cost.
- FIG. 1 is a perspective view according to a first embodiment of the present invention, in which a part of a code type thermal fuse has been cut off;
- FIG. 2 is a sectional view of an elastic core serving as an element of code type thermal fuse according to the first embodiment of the present invention
- FIG. 3 is a perspective view according to a second embodiment of the present invention, in which a part of a code type thermal fuse has been cut off.
- FIG. 4 is a perspective view according to a third embodiment of the present invention, in which a part of a code type thermal fuse has been cut off.
- FIG. 5 is a table according to the first and second embodiments of the present invention, showing results of various experiments in regard to examples 1 through 6, and comparative examples 1 and 2;
- FIG. 6 is a perspective view according to a fourth embodiment of the present invention, in which a part of a code type thermal fuse has been cut off.
- FIG. 7 is a table according to the fourth embodiment of the present invention, showing results of various experiments in regard to examples 7 through 10;
- FIG. 8 is a perspective view according to a fifth embodiment of the present invention, in which a part of a code type thermal fuse has been cut off.
- FIG. 9 is a sectional view of the code type thermal fuse according to the fifth embodiment of the present invention.
- FIG. 10 is a perspective view according to a sixth embodiment of the present invention, in which a part of a code type thermal fuse has been cut off.
- FIG. 11 is a perspective view according to a seventh embodiment of the present invention, in which a part of a code type thermal fuse has been cut off.
- FIG. 12 is a perspective view according to an eighth embodiment of the present invention, in which a part of a code type thermal fuse has been cut off.
- FIG. 13 is a table according to the fifth, sixth and seventh embodiments of the present invention, showing results of various experiments in regard to examples 11 through 14;
- FIG. 14 is a perspective view according to a ninth embodiment of the present invention, in which a part of a code type thermal fuse has been cut off.
- FIG. 15 is a perspective view according to a tenth embodiment of the present invention, in which a part of a code type thermal fuse has been cut off.
- FIG. 16 is a table according to the ninth and tenth embodiments of the present invention, showing results of various experiments in regard to examples 15 through 18.
- FIGS. 1, 2 and 5 A first embodiment of the present invention will be explained with reference to FIGS. 1, 2 and 5 .
- an elastic core 1 serving as an insulating core member, comprising a gas-containing material as a structural element.
- a tensile resistant member 1 a at the center thereof, of which outer periphery is covered by a gas-containing elastic member 1 b .
- a conductor 3 is wound on the outer periphery of the elastic core 1 , and a space layer 5 , comprising a glass braid, is provided on the outer peripheral side of the conductor 3 . Further, an insulating cover 7 covers the outer periphery of the space layer 5 .
- FIG. 1 shows them in a single circular shape as a typical model.
- the elastic core 1 and the conductor 3 serve as a fuse core 9 .
- there are several airtight spaces 11 inside the elastic member 1 b of the elastic core 1 and gas 13 is included in each airtight space 11 .
- the tensile resistant member 1 a has a function to improve the tensile strength and flexibility of a code type thermal fuse, and it is possible to use any known textile material as a practical material thereof.
- the elastic member 1 b is composed of ordinary elastomer material, etc., having the airtight spaces 11 , of which respective shapes are delomorphous or amorphous, preferably at least any part in the inside of the elastic member 1 b . It is possible to use, for example, foamed elastic material having isolated air holes, partially foamed elastic material, or elastic material having continuous holes in the length direction so that the airtight spaces 11 may be formed in the post-process.
- the elastic member 1 b as discussed above may be formed by any known method. There are various methods, for example, such as that the elastomer material serving as the elastic member 1 b has been mixed with organic foaming agent or inorganic foaming agent, and the mixture is heated and, thus foamed, whereby the foamed elastic member having isolated air holes can be formed.
- foamed elastic member by including gas during extrusion molding of elastomer material, or forming of partially foamed elastic member by adding sublimation material powder through heat-aging to elastomer material, or forming of the airtight spaces 11 , by preliminarily preparing elastic member having continuous holes in the length direction during contour extrusion of elastomer material, and in the post-process, by closing the continuous holes in the length direction at predetermined intervals through use of winding tension of the conductor 3 .
- the cross-sectional shape of the elastic core 1 is not limited in particular, but it is preferable, as illustrated in FIG. 2 , to provide a cross-sectional shape having a plurality (in the present embodiment, six) of protrusions 15 in the radial directions.
- This shape may be any polygon, or any starlike shape. Further, although polygonal shape or starlike shape has definite corners in general, the corners may also be in depressed and round shape.
- the conductor 3 can dig into the elastic core 1 easily, and it is preferable, because the conductor 3 may be cut immediately when the elastic core 1 is melted.
- the cross-sectional shape is polygon, it is preferable to select hexagon or less, because of easy digging of the conductor 3 .
- the conductor 3 it is possible to use, for example, metal thin wire selected from the group of low-melting point alloys and solder, or wire formed from conductive resin manufactured by filling high-density metal powder, metal oxide or carbon black, into thermoplastic resin such as olefin resin or polyamide resin.
- the preferable wire diameter of the conductor 3 is substantially from 0.04 mm to 0.8 mm, because an ordinary winding machine can wind such a conductor 3 around the elastic core 1 in the length direction.
- the flux may be included in the center of the conductor 3 , or the flux may be coated on the surface of the conductor 3 . It is possible to use ordinary rosin flux, or it is also possible to use flux having a small volume of activator.
- the conductor 3 has been wound around the elastic core 1 by applying tension, so that the conductor 3 may not at least be loose, thus the fuse core 9 is prepared.
- the each interval of winding the conductor 3 is, preferably, not less than one and half of the wire diameter, and more preferably, not less than twice and not more than 15 times. It is also possible to provide collective winding in the length direction by winding the parallel conductors 3 or by winding the stranded conductors 3 .
- the thus obtained fuse core 9 is covered by the insulating cover 7 via the space layer 5 , whereby the code type thermal fuse according to the present embodiment is completed.
- the insulating cover 7 it is possible to select any appropriate method from them, which can realize the working temperature lower than the melting temperature of the conductor 3 . It is possible to use the method, for example, in which a thermoplastic polymer such as ethylene copolymer workable at relatively low temperature, or a composition of chiefly comprising synthetic rubber such as ethylene propylene rubber, styrene butadiene rubber, butadiene rubber isoprene rubber or nitrile rubber, is cross-linked by using low-temperature cross-linking method such as radiation cross-linking or Silane cross-linking.
- a thermoplastic polymer such as ethylene copolymer workable at relatively low temperature
- synthetic rubber such as ethylene propylene rubber, styrene butadiene rubber, butadiene rubber isoprene rubber or nitrile rubber
- a forming method by using silicone rubber which can be extruded around normal temperature and which can be cross-linked at relatively low temperature, or a forming method, in which, after covering by braid of any textile material, the insulating varnish, parched at normal temperature, is coated.
- silicone rubber when used, it is also possible to provide a braid as exterior element in order to reinforce the mechanical strength of the insulating cover 7 .
- the insulating cover 7 may be provided, not only by the extrusion method as discussed above, but also by first forming a tubular insulating cover 7 separately, and thereafter, by inserting the fuse core 9 provided with the space layer 5 .
- the insulating cover 7 may be preferably thin, because of the increasing heat sensitivity, as long as the required characteristics such as the electric insulation ability and mechanical strength are satisfied.
- the insulating cover 7 is not in tight contact with the fuse core 9 , but covering with having the space layer 5 as discussed in the present embodiment. This is because, by providing the space layer 5 , the re-connection of the conductor 3 after detecting abnormal temperature may be prevented more effectively, and at the same time, the conductor 3 may be protected against the heat while the insulating cover 7 is provided.
- the space layer 5 may be formed by any known method, for example, in which the insulating cover 7 is provided around the fuse core 9 through tubing extrusion, or in which an insulating cover provided with protrusions on the inner periphery thereof is extruded in order to cover around the fuse core 9 , or in which a spacer is provided.
- these methods are disclosed in detail, in Japanese Unexamined Patent Applications Nos. Hei 5-128950, Hei 6-181028, Hei 7-176251, Hei 9-129120 and Hei 10-223105, all of which were filed by the applicant of the present invention. Thus, any of these methods may be used.
- the elastic core 1 was manufactured by the following methods. First, silicone varnishing was applied to a glass code having the outer diameter of about 0.7 mm, thus the tensile resistant member 1 a was provided. Thereafter, a silicone rubber, comprising a compound of 100 w/t parts (part by weight) of silicone rubber, 1 w/t part of foaming agent (AIBN) and 2 w/t parts of organic peroxide cross-linking agent kneaded on open roll, was extruded in order to cover the periphery of the tensile resistant member 1 a , so that the cross-section of the silicone rubber had six radial protrusions, of which inscribed circle was 1.6 mm and of which circumscribed circle was 1.8 mm. At the same time, the silicone rubber was foamed by applying hot-air vulcanization. Thus, the foamed elastic member 1 b , having isolated air holes, was formed.
- silicone rubber comprising a compound of 100 w/t parts (part by weight) of silicone rubber,
- two parallel conductors 3 respectively comprising 0.6 mm ⁇ of eutectic solder wire (melting temperature at 183° C.) in which flux had been included at the center, were drawn at the same tension and wound at an interval of 8.5 mm in the length direction around the corners of the elastic core 1 .
- non-alkali glass filaments each of which fiber diameter was about 9 ⁇ m, were stranded together in order to obtain a fiber bundle (yarn number: around #70), and this fiber bundle was braided by 16-yarn string manufacturing machine (using 16 yarns for manufacturing a single string), at braid coverage of about 17/25 mm, thus the space layer (glass braid) 5 was obtained.
- a mixture of ethylene copolymer, serving as the insulating cover 7 was extruded to form the cover at thickness of 0.5 mm and at extrusion temperature of 150° C., and thereafter, the cross-linking was done by applying electron beam thereto.
- the thus obtained code type thermal fuse was cut at length of about 20 cm, and the insulating cover 7 and the space layer (glass braid) 5 at each end were removed for about 1 cm respectively. Then, lead wires having the nominal cross-sectional area of 0.5 mm 2 , each of which was at length of 100 mm, were connected via crimp-type terminals, thus the code type thermal fuse assembly was manufactured.
- the code type thermal fuse assembly manufactured by the above method was inserted in a glass fiber braid tube at inner diameter of 4.0 mm and at length of about 15 cm, so that the code type thermal fuse part of the assembly may come to the center part of the tube. Thereafter, an electric current about 0.1 A was applied from 100 V AC power supply, by connecting incandescent bulb to the both terminals of the lead wires as an outer load. Then, the center part was heated from normal temperature, at temperature increase speed of 10° C./min. Thus, when the conductor 3 was disconnected, the temperature was checked.
- the manufactured code type thermal fuse assembly was placed in a hot-air circulation type of constant-temperature bath at temperature of 158° C., for 384 hours, whereby the deterioration due to aging by heat was prompted, and the flux was decomposed and removed by heat. Thereafter, the code type thermal fuse assembly after heat treatment was inserted in a glass fiber braid tube at inner diameter of 4.0 mm and at length of about 15 cm, so that the code type thermal fuse part of the assembly may come to the center part of the tube. Thereafter, an electric current about 0.1 A was applied from 100 V AC power supply, by connecting incandescent bulb to the both terminals of the lead wires as an outer load. Then, the center part was heated from initial temperature of 250° C., at temperature increase speed of 10° C./min. Thus, when the conductor 3 was disconnected, the temperature was checked.
- the tensile resistant member 1 a having isolated air holes, was formed by using silicone rubber to which 2 w/t parts of foaming agent (AIBN) were added.
- AIBN foaming agent
- the other materials and manufacturing method were substantially the same as those of Example 1, thus the code type thermal fuse was manufactured. Then the experiments, substantially the same as those of Example 1, were done for this code type thermal fuse, of which results are also included in FIG. 5 .
- the tensile resistant member 1 a was prepared by a glass code having the outer diameter of about 0.7 mm, to which silicone varnishing was not applied. Thereafter, a silicone rubber, comprising a compound of 100 w/t parts of silicone rubber, 3 w/t parts of polyacetal homopolymer powder (particles passed through 100-mesh sieve) and 2 w/t parts of organic peroxide cross-linking agent kneaded on open roll, was extruded in order to cover the periphery of the tensile resistant member 1 a , so that the cross-section of the silicone rubber had six radial protrusions, of which inscribed circle was 1.6 mm and of which circumscribed circle was 1.8 mm.
- the elastic core 1 at this stage was a silicone rubber elastic core including scattered polyacetal homopolymer powders, and there was no air hole in the inside thereof.
- the code type thermal fuse assembly was manufactured substantially by the same method as that of Example 1. Then, the manufactured code type thermal fuse assembly was placed in a hot-air circulation type of constant-temperature bath at temperature of 158° C., for 384 hours, whereby the deterioration due to aging by heat was prompted, thus the state after deterioration due to aging was reproduced. At this stage, the polyacetal homopolymer powder had been sublimed by heat, whereby the foamed elastic member 1 b having isolated air holes was formed.
- the insulating cover instead of using mixture of ethylene copolymer, mixture of ethylene propylene rubber was used, which was then extruded at temperature of 130° C. in order to form the cover.
- the other materials and manufacturing method were substantially the same as those of Example 1, thus the code type thermal fuse was manufactured. Then the experiments, substantially the same as those of Example 1, were done for this code type thermal fuse, of which results are also included in FIG. 5 .
- the elastic core was formed by using silicone rubber to which no foaming agent was added, and 0.6 mm ⁇ of eutectic solder wire without including flux was used as the conductor.
- the other materials and manufacturing method were substantially the same as those of Example 1, thus the code type thermal fuse was manufactured. Then the experiments, substantially the same as those of Example 1, were done for this code type thermal fuse, of which results are also included in FIG. 5 .
- the elastic core was formed by using silicone rubber to which no foaming agent was added, and 0.6 mm ⁇ of eutectic solder wire including flux at the center thereof was used as the conductor.
- the other materials and manufacturing method were substantially the same as those of Example 1, thus the code type thermal fuse was manufactured. Then the experiments, substantially the same as those of Example 1, were done for this code type thermal fuse, of which results are also included in FIG. 5 .
- the initial operative temperature of each Example is the melting temperature of the conductor 3 (183° C.).
- the other structure is substantially the same as that of the first embodiment as discussed above, and the identical numerals are allotted to the identical elements, and the explanation thereof will not be made.
- the initial operative temperature is the melting temperature of the conductor 3 (183° C.).
- a sheet type thermal fuse was manufactured, by placing the code type thermal fuse according to the first embodiment as discussed above, in a serpentine manner by any method such as that disclosed in Japanese Unexamined Patent Publication No. Sho 62-44394.
- Reference numeral 21 shows a double-faced adhesive paper, having a peeling paper 23 on one side.
- Reference numeral 25 shows the sheet type thermal fuse, positioned in a serpentine manner on the upper surface of the double-faced adhesive paper 21 .
- reference numeral 27 shows a metal foil covering the whole part of the sheet type thermal fuse 25 , and the metal foil 27 has been adhered to and fixed on the double-faced adhesive paper 21 .
- An acrylic adhesive paper is used as the double-faced adhesive paper 21 , and an aluminum foil at thickness of 100 ⁇ m is used as the metal foil 27 .
- the metal foil 27 and the double-faced adhesive paper 21 are used.
- the thus manufactured sheet type thermal fuse was attached to an iron panel at thickness of 0.5 mm, and the panel was placed in upright position.
- a commercially available wall paper was attached to the reverse side of the panel.
- 0.5 A of electric current was applied to the sheet type thermal fuse, and a burner was moved closer so that the burner flame was in contact with the panel. This state was maintained until the conductor of the thermal fuse was disconnected. Thereafter, the sheet type thermal fuse detected the heat, and was disconnected. After disconnection, there was no change, such as carbonization of the wall paper on the reverse side of the panel, and it was found that the thermal fuse expressed the effective performance.
- an insulating core member 101 has a tensile resistant member 101 a at the center, around which is covered by a polymer elastic member 101 b including the air.
- a conductor 3 is wound around the insulating core member 101 .
- the insulating core member 101 and the conductor 3 serve as a fuse core 105 .
- the fuse core 105 is covered by an insulating cover 107 .
- the insulating cover 107 has at least one or more (in the present embodiment, six) protrusions 109 , formed continuously or intermittently on the inner surface in the length direction.
- the insulating core member 101 is formed by any material, having characteristic of being not melted around the melting temperature of the conductor 103 , and also characteristic of expanding in the circumferential direction, for example, any metal wire to which insulation process has been applied, such as an electric wire in which thermoplastic polymer or thermoset polymer has been extruded on a conductor, or cable material comprising any polymer which has been formed by plastic extrusion of synthetic fiber, thermoplastic polymer or thermoset polymer, or any inorganic material such as ceramic fiber or glass fiber. Any one of the above materials may be used as a single material, but it is also possible to use a plurality of materials by applying the same tension thereto, or by stranding together, or by preparing composite material through combination of different material types.
- the tensile resistant member 101 a may be used for the purpose of improving the tensile strength and flexibility of the code type thermal fuse obtained by the present embodiment.
- the tensile resistant material 101 a may be formed by using any known textile material.
- the polymer elastic member 101 b including the air as discussed has the structure that delomorphous or amorphous airtight spaces have been formed, preferably at least any part in the inside of the elastic material comprising ordinary elastomer material, for example, silicone rubber, ethylene propylene rubber, natural rubber, isoprene rubber, acrylic rubber, fluorocarbon rubber, ethylene-vinyl acetate copolymer (EVA), ethylene-ethyl acrylate copolymer resin (EEA), or any thermoplastic elastomer (TPE).
- elastomer material for example, silicone rubber, ethylene propylene rubber, natural rubber, isoprene rubber, acrylic rubber, fluorocarbon rubber, ethylene-vinyl acetate copolymer (EVA), ethylene-ethyl acrylate copolymer resin (EEA), or any thermoplastic elastomer (TPE).
- foamed elastic material having isolated air holes, partially foamed elastic material, or elastic material having continuous holes in
- the elastic member 101 b as discussed above may be formed by any known method. There are various methods, for example, such as that the elastomer material serving as the elastic member has been mixed with organic foaming agent or inorganic foaming agent, and the mixture is heated and thus foamed, whereby the foamed elastic member having isolated air holes can be formed.
- foamed elastic member by including gas during extrusion molding of elastomer material, or forming of partially foamed elastic member by adding sublimation material powder through heat-aging to elastomer material, or forming of the airtight spaces, by preliminarily preparing elastic member having continuous holes in the length direction during contour extrusion of elastomer material, and in the post-process, by closing the continuous holes in the length direction through use of winding tension of the conductor, which will be explained afterwards.
- the conductor 103 it is possible to use, for example, metal thin wire selected from the group of low-melting point alloys and solder, or wire formed from conductive resin manufactured by filling high-density metal powder, metal oxide or carbon black, into thermoplastic resin such as olefin resin or polyamide resin.
- the preferable wire diameter of the conductor 103 is substantially from 0.04 mm to 2.0 mm, because an ordinary winding machine can wind such a conductor 103 around the elastic core in the length direction.
- the conductor 103 has been wound around the insulating core member 101 by applying tension, so that the conductor 103 may not at least be loose, thus the fuse core 105 is prepared. It is more preferable to select the polymer elastic member 101 b including the air as the insulating core member 101 , because the conductor 103 may dig into the insulating core member 101 sufficiently.
- the each interval of winding the conductor 103 is, preferably, not less than one and half of the wire diameter, and more preferably, not less than twice and not more than 15 times. It is also possible to provide collective winding in the length direction by winding the paralleled conductors 3 or by winding the stranded conductors 103 .
- the insulating cover 107 has at least one or more (in the present embodiment, six) protrusions 109 , formed continuously or intermittently on the inner surface in the length direction.
- the protrusions 109 have been provided because of the following reason.
- the protrusions 109 have further merits. As a predetermined space may be formed between the fuse core 105 and the insulating cover 107 , after the conductor 103 is disconnected by detecting abnormal temperature, it is possible to prevent re-connection of the conductor 3 by re-heating more effectively.
- the insulating cover 107 it is possible to select any appropriate method from them, which can be worked at lower temperature than the melting temperature of the conductor 103 . It is possible to use the method, for example, in which a thermoplastic polymer such as ethylene copolymer workable at relatively low temperature, or a synthetic rubber such as ethylene propylene rubber, styrene butadiene rubber, isoprene rubber or nitrile rubber, is cross-linked by using low-temperature cross-linking method such as radiation cross-linking. Further, it is also possible to use a forming method by using silicone rubber which can be extruded around normal temperature and which can be cross-linked at relatively low temperature.
- a thermoplastic polymer such as ethylene copolymer workable at relatively low temperature
- a synthetic rubber such as ethylene propylene rubber, styrene butadiene rubber, isoprene rubber or nitrile rubber
- the insulating cover 107 may be provided, not only by the extrusion method as discussed above, but also by first forming a tubular insulating cover 107 separately, and thereafter, by inserting the fuse core 105 .
- the insulating cover 107 may be preferably thin, because of the increasing heat sensitivity, as long as the required characteristics such as the electric insulation ability and mechanical strength are satisfied. It is preferable that the size of each protrusion 109 protruding in the circumferential direction is smaller because of the increasing heat sensitivity, as long as the required characteristic in order to prevent the re-connection is satisfied.
- the insulating core member 101 when the temperature increases, the insulating core member 101 is expanded in the circumferential direction, and presses the conductor 103 toward the protrusions 109 on the inner periphery of the insulating cover 107 , whereby the conductor 103 may be disconnected more surely during melting or just before melting thereof.
- the original function of flux the function to improve the detecting accuracy
- any deterioration, such as forming of oxide appears on the surface of the conductor 103 due to long-term use thereof and the melting disconnection cannot be done easily.
- As the structure of parts is not changed from conventional structure, and no complicated structure is required. Thus, it is possible to provide cost-effective products.
- silicone varnishing was applied to a glass code having the outer diameter of about 0.7 mm, thus the tensile resistant member 101 a was provided.
- a silicone rubber comprising a compound of 100 w/t parts of silicone rubber, 1 w/t part of foaming agent (AIBN) and 2 w/t parts of organic peroxide cross-linking agent kneaded on open roll, was extruded in order to cover the periphery of the tensile resistant member 101 a , so that the cross-section of the outer diameter was 1.8 mm.
- the silicone rubber was foamed by applying hot-air vulcanization.
- the insulating core member 101 was formed.
- two parallel conductors 103 respectively comprising 0.5 mm ⁇ of non-lead solder wire (tin-copper alloy, melting temperature at 217° C.) in which flux had been included at the center, were drawn at the same tension and wound at winding pitch of 5 times/10 mm (4 times the wire diameter) in the length direction around the insulating core member 101 .
- a mixture of ethylene copolymer serving as the insulating cover 107 was extruded at temperature of 150° C., so that the six protrusions 109 , of which respective width was 0.6 mm and height was 0.3 mm, and of which thickness was 0.3 mm, were provided.
- the cross-linking was done by applying electron beam thereto.
- the thus obtained code type thermal fuse was cut at length of about 20 cm, and each end of the insulating cover 107 was removed for about 1 cm. Then, lead wires having the nominal cross-sectional area of 0.5 mm 2 , each of which was at length of 100 mm, were connected via crimp-type terminals, thus the code type thermal fuse assembly was manufactured.
- the outer diameter of the insulating core member 101 was changed from 1.8 mm to 2.2 mm.
- the other manufacturing method was substantially the same as that of Example 7, thus the code type thermal fuse was manufactured.
- the experiments, substantially the same as those of Examples 1 and 2, were done for this code type thermal fuse, of which results are also included in FIG. 7 .
- the outer diameter of the insulating core member 101 was changed from 1.8 mm to 2.2 mm, and the height of each protrusion 109 was also changed from 0.3 mm to 0.5 mm.
- the other manufacturing method was substantially the same as that of Example 7, thus the code type thermal fuse was manufactured. Then the experiments, substantially the same as those of Examples 1 and 2, were done for this code type thermal fuse, of which results are also included in FIG. 7 .
- the initial operative temperature of each Example is the melting temperature of the conductor (217° C.).
- the operative temperature of the code type thermal fuse according to Examples 7 through 9 becomes lower, in which the insulating core member 101 , comprising the material having characteristic of expanding in the circumferential direction, is combined with the insulating cover 107 having the protrusions 109 on the inner surface.
- the operative temperature was the lowest. This is because the space between the insulating core member 101 and the protrusions 109 becomes narrower, and because the pressure against the conductor 103 becomes larger due to increase of expanding volume of the insulating core member 101 .
- Example 9 With reference to Example 9 in which the height of the protrusions 109 was larger, the operative temperature was good, but as compared with Examples 7 and 8, the operative temperature was rather higher. This is because, as the protrusions 109 became larger, it became more difficult to transfer the heat from the outside to the conductor 103 correspondingly, thus the heat sensitivity became poor.
- the code type thermal fuse according to Example 10 in which there was no protrusion 109 on the inner surface of the insulating cover 107 , the operative temperature became relatively higher. This is because, as there was no protrusion 109 , it was difficult to apply pressure, generated by expansion of the insulating core member 101 , to the conductor 103 .
- an insulating core member 201 comprising a tensile resistant member 201 a and a cover member 201 b .
- the tensile resistant member 201 a was provided by applying silicone varnishing to a glass code having the outer diameter of about 0.7 mm. Further, a compound of 100 w/t parts of silicone rubber, 1 w/t part of foaming agent (AIBN) and 2 w/t parts of organic peroxide cross-linking agent kneaded on open roll, is used for the cover member 201 b .
- the cover member 201 b is extruded in order to cover the periphery of the tensile resistant member 201 a , so that the cross-section of the outer diameter is 1.8 mm.
- the silicone rubber is foamed by applying hot-air vulcanization.
- the insulating core member 201 is formed.
- Each conductor 203 comprises 0.5 mm ⁇ of non-lead solder wire (tin-copper alloy, melting temperature at 217° C.) in which flux had been included at the center, and two of which are drawn at the same tension and wound at winding pitch of 5 times/10 mm (4 times the wire diameter) in the length direction around the insulating core member 201 , so that the conductors 203 may dig into the insulating core member 201 sufficiently.
- a fuse core 207 comprising a line-shaped insulator 205 wound around the outer periphery of the conductor 203 in the length direction.
- a monofilament of 0.4 mm ⁇ polyphenylene sulfide is used, and the line-shaped insulator 205 is wound in the length direction, reverse to that of the conductor 203 , at winding pitch of 10 times/32 mm (8 times the wire diameter).
- the outer periphery of the thus obtained fuse core 207 is covered by tubular insulating cover 209 .
- the insulating cover 209 a mixture of ethylene copolymer serving has been extruded at temperature of 150° C., in a tubular shape having the thickness of 0.3 mm and the outer diameter of 4.2 mm. Thereafter, the cross-linking is done by applying electron beam thereto, thus the code type thermal fuse according to the present embodiment is obtained.
- the insulating core member 201 is formed by any material, having characteristic of being not melted around the melting temperature of the conductor 203 , and also characteristic of expanding in the circumferential direction, for example, any metal wire to which insulation process has been applied, such as an electric wire in which thermoplastic polymer or thermoset polymer has been extruded on a conductor, or cable material comprising any polymer which has been formed by plastic extrusion of synthetic fiber, thermoplastic polymer or thermoset polymer, or any inorganic material such as ceramic fiber or glass fiber. Any one of the above materials may be used as a single material, but it is also possible to use a plurality of materials by winding the parallel conductors 3 , or by stranding together, or by preparing composite material through combination of different material types.
- the tensile resistant material 201 a may be formed by using any known textile material.
- a polymer material including the air, serving as the cover member 201 b may have the structure that delomorphous or amorphous airtight spaces have been formed, preferably at least any part in the inside of polymer material comprising such as elastomer.
- any ordinary elastomer material for example, silicone rubber, ethylene propylene rubber, natural rubber, isoprene rubber, acrylic rubber, fluorocarbon rubber, ethylene-vinyl acetate copolymer (EVA), ethylene-ethyl acrylate copolymer resin (EEA), or any thermoplastic elastomer (TPE).
- silicone rubber ethylene propylene rubber, natural rubber, isoprene rubber, acrylic rubber, fluorocarbon rubber, ethylene-vinyl acetate copolymer (EVA), ethylene-ethyl acrylate copolymer resin (EEA), or any thermoplastic elastomer (TPE).
- the conductor 203 it is possible to use, for example, metal thin wire selected from the group of low-melting point alloys and solder, or wire formed from conductive resin manufactured by filling high-density metal powder, metal oxide or carbon black, into thermoplastic resin such as olefin resin or polyamide resin.
- the preferable wire diameter of the conductor 203 is substantially from 0.4 mm to 2.0 mm, because an ordinary winding machine can wind such a conductor 203 around the insulating core member 201 in the length direction.
- the conductor 203 may be prepared by using a single conductor, or by using a plurality of paralleled materials through application of the same tension thereto, or by using a plurality of stranded materials.
- the line-shaped insulator 205 is formed by any material, having characteristic of being not melted at the melting temperature of the conductor 203 , for example, a wire material comprising any polymer material in which synthetic fiber, thermoplastic polymer or thermoset polymer, such as aliphatic polyamide, aramid, polyethylene terephthalate, wholly aromatic polyester or novoloid has been formed by plastic extrusion, or a wire material comprising any inorganic material such as ceramic fiber or glass fiber. Any one of the above materials may be used as a single material, but it is also possible to use a plurality of materials by applying the same tension thereto, or by stranding together, or by preparing composite material through combination of different material types.
- the line-shaped insulator 205 may squeeze the conductor 203 , whereby the disconnection of the conductor 203 may be done more securely.
- any synthetic fiber such as aliphatic polyamide, aramid, polyethylene terephthalate or polybutylene terephthalate, or any fiber formed by high drawing of any of these synthetic fibers, or any thermoplastic resin such as polyethylene, polypropylene, aliphatic polyamide, polyethylene terephthalate, propylene fluoroethylene, vinylidene fluoride or ethylene-tetrafluoroethylene copolymer, which has been extruded in the shape of wire and drawn thereafter, or a wire material which has been formed by annealing of synthetic resin, such as polyacetal, of which contracting rate is relatively large.
- any synthetic fiber such as aliphatic polyamide, aramid, polyethylene terephthalate or polybutylene terephthalate, or any fiber formed by high drawing of any of these synthetic fibers
- any thermoplastic resin such as polyethylene, polypropylene, aliphatic polyamide, polyethylene terephthalate, propylene fluoroethylene, vinylidene fluor
- the line-shaped insulator 205 having characteristic of expanding in the circumferential direction around the melting temperature of the conductor 203 . Accordingly, the insulating core member 201 is expanded in the circumferential direction and presses the conductor 203 against the line-shaped insulator 205 , and at the same time, the line-shaped insulator 205 is also expanded and presses the conductor 203 against the insulating core member 201 , and these characteristics are preferable because the disconnection of the conductor 203 may be done more securely.
- the line-shaped insulator 205 having characteristic of expanding in the circumferential direction, it is possible to use any material of which positive expansion coefficient is large, for example, foamed cross-linked rubber, or cross-linked rubber including any foaming material such as ADCA, exfoliated graphite or low-boiling liquid contained in micro capsule, or cross-linked rubber formed by knealing and incorporating relatively low-boiling organic solvent in rubber, and after extrusion, formed by vaporizing the incorporated organic solvent by heat, or any material which has been formed by blowing a high-compression gas at the same time of extrusion molding of a synthetic resin, or a cross-linked rubber, which has been formed by adding heat sublimation material powder to an elastomer material, and thereafter, by heat sublimation of the added powder, or a cross-linked rubber, which has been formed by preliminarily preparing elastic member having continuous holes in the length direction during contour extrusion of elastomer material, and in the post-process, by closing the foam
- the insulating cover 209 it is possible to select any appropriate material and method from them, which can realize the working temperature lower than the melting temperature of the conductor 203 . It is possible to use the method, for example, in which a thermoplastic polymer such as ethylene copolymer workable at relatively low temperature, or a synthetic rubber such as ethylene propylene rubber, styrene butadiene rubber, isoprene rubber or nitrile rubber, is cross-linked by using low-temperature cross-linking method such as radiation cross-linking. Further, it is also possible to use a forming method by using silicone rubber which can be extruded around normal temperature and which can be cross-linked at relatively low temperature.
- a thermoplastic polymer such as ethylene copolymer workable at relatively low temperature
- a synthetic rubber such as ethylene propylene rubber, styrene butadiene rubber, isoprene rubber or nitrile rubber
- the silicone rubber when used, it is also possible to provide a braid as exterior element in order to reinforce the mechanical strength of the insulating cover 209 .
- the insulating cover 209 may be preferably thin, because of the increasing heat sensitivity, as long as the required characteristics such as the electric insulation ability and mechanical strength are satisfied.
- FIG. 10 There is a conductor 303 , substantially the same as that of the fifth embodiment as discussed above, around which a line-shaped insulator 305 , also substantially the same as that of the fifth embodiment, is wound in the length direction at winding pitch of 10 times/16 mm (4 times the wire diameter).
- the conductor 303 around which the line-shaped insulator 305 has been wound in the length direction, is also wound around an insulating core member 301 , substantially the same as that of the fifth embodiment, at winding pitch of 10 times/85 mm (6.5 times the wire diameter), thus a fuse core 307 is obtained.
- a tubular insulating cover 309 covering the outer periphery of the fuse core 307 .
- the material of the insulating cover 309 is substantially the same as that of the fifth embodiment. Accordingly, a code type thermal fuse according to the present embodiment is obtained.
- an insulating core member 401 formed from a compound of 100 w/t parts of silicone rubber, 1 w/t part of foaming agent (AIBN) and 2 w/t parts of organic peroxide cross-linking agent kneaded on open roll. Then, this material for manufacturing the insulating core member 401 is extruded, so that the cross-section of the outer diameter is 1.2 mm. At the same time, the silicone rubber is foamed by applying hot-air vulcanization. Thus, the insulating core member 401 is formed.
- the insulating core member 401 , a conductor 403 and a line-shaped insulator 405 are stranded together at pitch of 3.0 mm, thus a fuse core 407 is obtained.
- tubular insulating cover 409 covering the outer periphery of the fuse core 407 .
- the material of the insulating cover 409 is substantially the same as that of the fifth embodiment. Accordingly, a code type thermal fuse according to the present embodiment is obtained.
- FIG. 12 there is a braid 505 , substantially serving as the line-shaped insulator of the fifth embodiment.
- the other structure is substantially the same as that of the fifth embodiment as discussed above, and the identical numerals are allotted to the identical elements, and the explanation thereof will not be made.
- the fifth through eighth embodiments as discussed above have the following merits.
- the insulating core members 201 , 301 and 401 are expanded in the circumferential direction due to increase of temperature, and presses the conductors 203 , 303 and 403 against the line-shaped insulators 205 , 305 and 405 or against the braid 505 . Accordingly, the conductors 203 , 303 and 403 can be disconnected more securely during melting of just before melting. Thus, even when the original function of flux (the function to improve the detecting accuracy) is deteriorated due to aging by heat, etc., it is still possible to maintain the good disconnection time.
- the conductors 203 , 303 and 403 are covered by the tubular insulating covers 209 , 309 and 409 , there are so much space around the conductors 203 , 303 and 403 , that the conductors 203 , 303 and 403 may be deformed. Accordingly, as the melted conductors 203 , 303 and 403 are multiplied separately, the disconnection of the conductors 203 , 303 and 403 will not be inhibited.
- the conductor 203 is wound around the insulating core member 201 in the length direction, and that the other line-shaped insulator 205 is wound in the length direction reverse to that of the conductor 203 . It is also possible, for example, to use a plurality of the line-shaped insulators 205 . Further, it is also possible to wind the line-shaped insulator 205 and the conductor 203 in the same length direction, as long as the winding pitch of the line-shaped insulator 205 is different from that of the conductor 203 . It is also possible to add the line-shaped insulator 205 directly along the longitudinal direction.
- the conductor 203 for example, it is also possible to add the conductor 203 to the insulating core member 201 directly along the longitudinal direction.
- the explanation is made as for an example of winding a single line-shaped insulator 305 around the conductor 303 in the length direction, and then winding this unit around the insulating core member 301 in the length direction.
- the explanations are made as for examples of winding the conductors 203 , 303 or line-shaped insulators 205 , 305 around the insulating core members 201 , 301 in the length direction. Further, according to the seventh embodiment, the explanation is made as for an example of stranding the insulating core member 401 , the conductor 403 and the line-shaped insulator 405 together. It is also possible, for example, to use the conductor 203 wound around the insulating core member 205 in the length direction, or to use the insulating core member 201 and the conductor 203 stranded together in advance.
- each example is essentially characterized in that, as illustrated in FIG. 9 , at least a part of the fuse core 207 ( 307 , 407 ) in the length direction has the structure that the conductor 203 ( 303 , 403 ) is sandwiched between the insulating core member 201 ( 301 , 401 ) and the line-shaped insulator 205 ( 305 , 405 or the braid 505 ).
- Example 11 corresponding to the fifth embodiment
- Example 12 corresponding to the sixth embodiment
- Examples 13 and 14 corresponding to the seventh embodiment, of which explanation will be done as follows.
- the line-shaped insulator 205 was not used in regard to the fifth embodiment.
- each of the code type thermal fuses according to Examples 11 through 14 was cut at length of about 20 cm, and each end of the insulating cover was removed for about 1 cm. Then, lead wires having the nominal cross-sectional area of 0.5 mm 2 , each of which was at length of 100 mm, were connected via crimp-type terminals, thus the code type thermal fuse assembly was manufactured.
- the elastic core 601 including the air
- the elastic core 601 has a tensile resistant member 601 a at the center, around which is covered by an elastic member 601 b including the air.
- a conductor 603 is wound around the elastic core 601
- an insulating cover 607 is wound around the conductor 603 .
- the elastic core 601 and the conductor 603 serve as a fuse core 609 .
- the insulating cover 607 has at least one or more (in the present embodiment, six) protrusions 611 , formed continuously or intermittently on the inner surface in the length direction.
- the insulating cover 607 has characteristic of contracting in the inward circumferential direction, and the material thereof is not limited, as long as the material belongs to pyrolysis polymer, and a plurality of material types may also be mixed with each other. It is possible to use, for example, any resin material such as polyester resin, polyamide resin, polyolefin resin (ethylene copolymer) or fluorocarbon resin, or any elastomer material such as nitrile rubber, ethylene propylene rubber, chloroprene rubber, acrylic rubber, silicone rubber or fluorocarbon rubber.
- any resin material such as polyester resin, polyamide resin, polyolefin resin (ethylene copolymer) or fluorocarbon resin, or any elastomer material such as nitrile rubber, ethylene propylene rubber, chloroprene rubber, acrylic rubber, silicone rubber or fluorocarbon rubber.
- a mixture of ethylene propylene rubber with polyolefin resin (ethylene copolymer) at the mixing rate of 1:1 has been prepared, with which additives such as fire retardant, antioxidant, lubricant, cross-linking aids, etc., have been further mixed.
- the contracting speed of the insulating cover 607 can be adjusted by pyrolysis temperature.
- the pyrolysis temperature is high (i.e. when the mixture has much material having high pyrolysis temperature)
- the contracting speed will become lower.
- the pyrolysis temperature is low (i.e. when the mixture has much material having low pyrolysis temperature)
- the contracting speed will become higher. Therefore, it is possible to determine the speed appropriately according to the using condition.
- the other structure is substantially the same as that of the fourth embodiment as discussed above, and the identical numerals are allotted to the identical elements, and the explanation thereof will not be made.
- a space layer 605 comprising a glass braid is provided on the outer peripheral side of the conductor 603 .
- the other structure is substantially the same as that of the ninth embodiment as discussed above, and the identical numerals are allotted to the identical elements, and the explanation thereof will not be made.
- Example 15 the characteristic evaluation test was done for Examples 15, 16 and 17 corresponding to the ninth embodiment, and Example 18 corresponding to the tenth embodiment, of which explanation will be done as follows.
- the structure of each Example is substantially the same as that of Example 7 corresponding to the fourth embodiment as discussed above, except for the insulating cover 607 of Example 15.
- the elastic member 601 b was not kneaded with foaming agent (AIBN), whereby the conductor 603 was disconnected only by contracting of the insulating cover 607 .
- AIBN foaming agent
- Example 17 with reference to Example 15, an eutectic solder wire (melting temperature at 183° C.) at diameter of 0.6 mm was used as the conductor 603 .
- each of the code type thermal fuses according to Examples 15 through 18 was cut at length of about 20 cm, and each end of the insulating cover was removed for about 1 cm. Then, lead wires having the nominal cross-sectional area of 0.5 mm 2 , each of which was at length of 100 mm, were connected via crimp-type terminals, thus the code type thermal fuse assembly was manufactured.
- the protrusions are provided on the inner periphery of the insulating cover 607 .
- the present invention relates to the code type thermal fuse and a sheet type thermal fuse, which can be disconnected when any part thereof is exposed in an abnormal high temperature state, so that the abnormal temperature can be detected. More particularly, the present invention relates to the code type thermal fuse and the sheet type thermal fuse, of which disconnection time is still good even after being deteriorated due to aging by heat, and which has good operative reliability.
- the present invention may be used for various purposes, for example, refrigerators, indoor and outdoor equipment of air conditioners, cloth drying machines, rice cookers with keep-warm function, hot plates, coffee brewers, water heaters, ceramic heaters, oil heaters, automatic dispensers, electric blankets, floor heating panels, copying machines, facsimile machines, dishwashers, fryers, etc.
Abstract
A code type thermal fuse, comprising a fuse core produced by winding a conductor meltable at a predetermined temperature on an insulating core member continuous in the length direction, and an insulating cover covering the outer periphery of the fuse core, wherein the conductor can be cut by expanding the insulating core member at a predetermined temperature and/or by contracting the insulating cover at the predetermined temperature.
Description
- The present invention relates to a code type thermal fuse and a sheet type thermal fuse, which can be disconnected when any part thereof is exposed in an abnormal high temperature state, so that the abnormal temperature can be detected. More particularly, the present invention relates to the code type thermal fuse and the sheet type thermal fuse, of which disconnection time is still good even after being deteriorated due to aging by heat, and which has good operative reliability.
- For example, according to Japanese Unexamined Patent Publication No. Hei 6-181028, there has been disclosed a code type thermal fuse, comprising a space layer and an insulating cover layer around a center core member, on which a conductor meltable at a predetermined temperature is wound in the lateral direction on an elastic core. There are lead wires connected to the both ends of the conductor via terminals, and when the conductor melts at excessive temperature the electric connection between the lead wires is cut, whereby the abnormal state is detected.
- According to Japanese Unexamined Patent Publication No. Hei 7-306750, there has also been disclosed a code type thermal fuse, substantially having the same structure.
- According to Japanese Unexamined Patent Publication No. 2000-231866, there has been disclosed a code type thermal fuse, wherein a core wire, comprising a metal wire meltable at a predetermined temperature, is wound in the lateral direction with predetermined intervals on a core member and is inserted into a protection tube. The protection tube comprises a glass braid sleeve covered by an extruded silicone rubber.
- With regard to these code type thermal fuses, to promote the flow of the melted conductor or the metal wire during opening of the fuse, so as to improve the detecting accuracy, flux was applied to the conductor or the metal wire.
- However, according to these types of code type thermal fuses, since there have been high-integration of structure of combustion apparatus, the thermal ambience during long-term use becomes severer. Thus, the deterioration of flux would be prompted due to aging by heat, or the reliability of conductor would be lowered by heat, and it should be foreseen that a quick response to temperature would not be obtained after deterioration due to thermal aging.
- Although attempts have been made to improve reliability for example, according to the code type thermal fuse of Japanese Unexamined Patent Publication No. 2000-231866, there has been disclosed, as means to solve the problem, only the silicone rubber material, of which mechanical strength is normally low, and which requires reinforcing means as an exterior element. Thus, when the protection tube is ripped and damaged by edges, etc. of metal parts inside the combustion apparatus, there would be a higher risk of electric leakage by intrusion of water, and also a higher risk of prompted deterioration of flux due to aging by intrusion of exhaust gas.
- In the light of the above problems, it is an object of the present invention to provide code type thermal fuse, which can be disconnected when any part thereof is exposed in an abnormal high temperature state, so that the abnormal temperature can be detected accurately, in particular, of which disconnection time is still good even after being deteriorated due to aging by heat, and also to provide a sheet type thermal fuse, substantially having the same characteristic as that of the code type thermal fuse as mentioned above.
- To achieve the objects mentioned above, according to
claim 1 of the present invention, there is provided a code type thermal fuse comprising: a fuse core produced by winding a conductor meltable at a predetermined temperature on an insulating core member continuously provided in the length direction and an insulating cover covering the outer periphery of the fuse core, characterized in that: the conductor can be cut by expanding the insulating core member at a predetermined temperature and/or by contracting the insulating cover at the predetermined temperature. - According to
claim 2 of the present invention, there is provided code type thermal fuse as claimed inclaim 1, further characterized in that: the insulating core member has at least one or more protrusions formed continuously or intermittently in the length direction on the outer periphery of the insulating core member. - According to
claim 3 of the present invention, there is provided the code type thermal fuse as claimed inclaim 1 orclaim 2, further characterized in that: the insulating cover has at least one or more protrusions formed continuously or intermittently in the length direction on the inner periphery of the insulating cover. - According to
claim 4 of the present invention, there is provided the code type thermal fuse as claimed inclaim 1, further characterized in that: another line-shaped or braid-shaped insulator is provided on the inner peripheral side of the insulating cover; and the conductor is sandwiched between the insulating core member and the line-shaped or braid-shaped insulator at least partially in the length direction of the conductor. - According to
claim 5 of the present invention, there is provided the code type thermal fuse as claimed inclaim 4, further characterized in that: the line-shaped or braid-shaped insulator has a characteristic of contracting in the length direction around the melting temperature of the conductor. - According to
claim 6 of the present invention, there is provided the code type thermal fuse as claimed inclaim 4, further characterized in that: the line-shaped or braid-shaped insulator has a characteristic of expanding in the peripheral direction around a melting temperature of the conductor. - According to
claim 7 of the present invention, there is provided the code type thermal fuse as claimed in any one claim ofclaim 1 throughclaim 6, further characterized in that: the insulating core member comprises a gas-containing material as a structural element. - According to
claim 8 of the present invention, there is provided the code type thermal fuse as claimed inclaim 7, further characterized in that: the insulating core member comprises a gas-containing material covering a periphery of a tensile resistant member at the center of the insulating core member. - According to
claim 9 of the present invention, there is provided a sheet type thermal fuse, comprising: the code type thermal fuse according to any one claim ofclaim 1 throughclaim 8, provided on a flat surface in a serpentine manner; and means for fixing a layout of the code type thermal fuse. - Accordingly, it is possible to obtain the code type thermal fuse, which is surely disconnected at abnormal high temperature even at any position to which any compression force is not applied, and after disconnection, which has no risk of re-contact by melted conductor, etc., whereby any inappropriate operation is prevented. Further, it is also possible to obtain the sheet type thermal fuse substantially having the same characteristic as that of the code type thermal fuse as mentioned above.
- The thermal fuse of the present invention may further serve, not only for prevention of deterioration of operative reliability due to lost of flux function under practical using conditions, but also for improvement of operative reliability of aged code type thermal fuse, against such as formation of surface oxide film due to thermal oxidization of conductor.
- In addition, the thermal fuse of the present invention is useful, because there is substantially no change of the structure of such a thermal fuse as compared with that of conventional thermal fuses assembly, it is also possible to use widely as a safety device for various heat apparatus, by not increasing the production cost.
-
FIG. 1 is a perspective view according to a first embodiment of the present invention, in which a part of a code type thermal fuse has been cut off; -
FIG. 2 is a sectional view of an elastic core serving as an element of code type thermal fuse according to the first embodiment of the present invention; -
FIG. 3 is a perspective view according to a second embodiment of the present invention, in which a part of a code type thermal fuse has been cut off. -
FIG. 4 is a perspective view according to a third embodiment of the present invention, in which a part of a code type thermal fuse has been cut off. -
FIG. 5 is a table according to the first and second embodiments of the present invention, showing results of various experiments in regard to examples 1 through 6, and comparative examples 1 and 2; -
FIG. 6 is a perspective view according to a fourth embodiment of the present invention, in which a part of a code type thermal fuse has been cut off. -
FIG. 7 is a table according to the fourth embodiment of the present invention, showing results of various experiments in regard to examples 7 through 10; -
FIG. 8 is a perspective view according to a fifth embodiment of the present invention, in which a part of a code type thermal fuse has been cut off. -
FIG. 9 is a sectional view of the code type thermal fuse according to the fifth embodiment of the present invention; -
FIG. 10 is a perspective view according to a sixth embodiment of the present invention, in which a part of a code type thermal fuse has been cut off. -
FIG. 11 is a perspective view according to a seventh embodiment of the present invention, in which a part of a code type thermal fuse has been cut off. -
FIG. 12 is a perspective view according to an eighth embodiment of the present invention, in which a part of a code type thermal fuse has been cut off. -
FIG. 13 is a table according to the fifth, sixth and seventh embodiments of the present invention, showing results of various experiments in regard to examples 11 through 14; -
FIG. 14 is a perspective view according to a ninth embodiment of the present invention, in which a part of a code type thermal fuse has been cut off. -
FIG. 15 is a perspective view according to a tenth embodiment of the present invention, in which a part of a code type thermal fuse has been cut off. and -
FIG. 16 is a table according to the ninth and tenth embodiments of the present invention, showing results of various experiments in regard to examples 15 through 18. - A first embodiment of the present invention will be explained with reference to
FIGS. 1, 2 and 5. - There is an
elastic core 1 serving as an insulating core member, comprising a gas-containing material as a structural element. There is a tensileresistant member 1 a at the center thereof, of which outer periphery is covered by a gas-containingelastic member 1 b. Aconductor 3 is wound on the outer periphery of theelastic core 1, and aspace layer 5, comprising a glass braid, is provided on the outer peripheral side of theconductor 3. Further, aninsulating cover 7 covers the outer periphery of thespace layer 5. - For reference, as illustrated in
FIG. 2 , although the tensileresistant member 1 a is actually composed of a plurality of fiber bundles,FIG. 1 shows them in a single circular shape as a typical model. - The
elastic core 1 and theconductor 3 serve as afuse core 9. As illustrated inFIG. 2 , there are severalairtight spaces 11 inside theelastic member 1 b of theelastic core 1, andgas 13 is included in eachairtight space 11. - The tensile
resistant member 1 a has a function to improve the tensile strength and flexibility of a code type thermal fuse, and it is possible to use any known textile material as a practical material thereof. - The
elastic member 1 b is composed of ordinary elastomer material, etc., having theairtight spaces 11, of which respective shapes are delomorphous or amorphous, preferably at least any part in the inside of theelastic member 1 b. It is possible to use, for example, foamed elastic material having isolated air holes, partially foamed elastic material, or elastic material having continuous holes in the length direction so that theairtight spaces 11 may be formed in the post-process. - The
elastic member 1 b as discussed above may be formed by any known method. There are various methods, for example, such as that the elastomer material serving as theelastic member 1 b has been mixed with organic foaming agent or inorganic foaming agent, and the mixture is heated and, thus foamed, whereby the foamed elastic member having isolated air holes can be formed. Further, it is also possible to use other methods, such as forming of foamed elastic member by including gas during extrusion molding of elastomer material, or forming of partially foamed elastic member by adding sublimation material powder through heat-aging to elastomer material, or forming of theairtight spaces 11, by preliminarily preparing elastic member having continuous holes in the length direction during contour extrusion of elastomer material, and in the post-process, by closing the continuous holes in the length direction at predetermined intervals through use of winding tension of theconductor 3. - The cross-sectional shape of the
elastic core 1 is not limited in particular, but it is preferable, as illustrated inFIG. 2 , to provide a cross-sectional shape having a plurality (in the present embodiment, six) ofprotrusions 15 in the radial directions. This shape may be any polygon, or any starlike shape. Further, although polygonal shape or starlike shape has definite corners in general, the corners may also be in depressed and round shape. According to these cross-sectional shapes, compared with the circular cross-sectional shape, theconductor 3 can dig into theelastic core 1 easily, and it is preferable, because theconductor 3 may be cut immediately when theelastic core 1 is melted. When the cross-sectional shape is polygon, it is preferable to select hexagon or less, because of easy digging of theconductor 3. - As for the
conductor 3, it is possible to use, for example, metal thin wire selected from the group of low-melting point alloys and solder, or wire formed from conductive resin manufactured by filling high-density metal powder, metal oxide or carbon black, into thermoplastic resin such as olefin resin or polyamide resin. The preferable wire diameter of theconductor 3 is substantially from 0.04 mm to 0.8 mm, because an ordinary winding machine can wind such aconductor 3 around theelastic core 1 in the length direction. - It is also possible to apply flux to the
conductor 3. The flux may be included in the center of theconductor 3, or the flux may be coated on the surface of theconductor 3. It is possible to use ordinary rosin flux, or it is also possible to use flux having a small volume of activator. - The
conductor 3 has been wound around theelastic core 1 by applying tension, so that theconductor 3 may not at least be loose, thus thefuse core 9 is prepared. The each interval of winding theconductor 3 is, preferably, not less than one and half of the wire diameter, and more preferably, not less than twice and not more than 15 times. It is also possible to provide collective winding in the length direction by winding theparallel conductors 3 or by winding the strandedconductors 3. - The thus obtained
fuse core 9 is covered by the insulatingcover 7 via thespace layer 5, whereby the code type thermal fuse according to the present embodiment is completed. - As there are various known methods in regard to the insulating
cover 7, it is possible to select any appropriate method from them, which can realize the working temperature lower than the melting temperature of theconductor 3. It is possible to use the method, for example, in which a thermoplastic polymer such as ethylene copolymer workable at relatively low temperature, or a composition of chiefly comprising synthetic rubber such as ethylene propylene rubber, styrene butadiene rubber, butadiene rubber isoprene rubber or nitrile rubber, is cross-linked by using low-temperature cross-linking method such as radiation cross-linking or Silane cross-linking. Further, it is also possible to use a forming method by using silicone rubber which can be extruded around normal temperature and which can be cross-linked at relatively low temperature, or a forming method, in which, after covering by braid of any textile material, the insulating varnish, parched at normal temperature, is coated. In particular, when the silicone rubber is used, it is also possible to provide a braid as exterior element in order to reinforce the mechanical strength of the insulatingcover 7. The insulatingcover 7 may be provided, not only by the extrusion method as discussed above, but also by first forming a tubular insulatingcover 7 separately, and thereafter, by inserting thefuse core 9 provided with thespace layer 5. The insulatingcover 7 may be preferably thin, because of the increasing heat sensitivity, as long as the required characteristics such as the electric insulation ability and mechanical strength are satisfied. - Preferably, the insulating
cover 7 is not in tight contact with thefuse core 9, but covering with having thespace layer 5 as discussed in the present embodiment. This is because, by providing thespace layer 5, the re-connection of theconductor 3 after detecting abnormal temperature may be prevented more effectively, and at the same time, theconductor 3 may be protected against the heat while the insulatingcover 7 is provided. - The
space layer 5 may be formed by any known method, for example, in which the insulatingcover 7 is provided around thefuse core 9 through tubing extrusion, or in which an insulating cover provided with protrusions on the inner periphery thereof is extruded in order to cover around thefuse core 9, or in which a spacer is provided. These methods are disclosed in detail, in Japanese Unexamined Patent Applications Nos. Hei 5-128950, Hei 6-181028, Hei 7-176251, Hei 9-129120 and Hei 10-223105, all of which were filed by the applicant of the present invention. Thus, any of these methods may be used. - Now several examples according to the first embodiment will be explained.
- The
elastic core 1 was manufactured by the following methods. First, silicone varnishing was applied to a glass code having the outer diameter of about 0.7 mm, thus the tensileresistant member 1 a was provided. Thereafter, a silicone rubber, comprising a compound of 100 w/t parts (part by weight) of silicone rubber, 1 w/t part of foaming agent (AIBN) and 2 w/t parts of organic peroxide cross-linking agent kneaded on open roll, was extruded in order to cover the periphery of the tensileresistant member 1 a, so that the cross-section of the silicone rubber had six radial protrusions, of which inscribed circle was 1.6 mm and of which circumscribed circle was 1.8 mm. At the same time, the silicone rubber was foamed by applying hot-air vulcanization. Thus, the foamedelastic member 1 b, having isolated air holes, was formed. - Thereafter, two
parallel conductors 3, respectively comprising 0.6 mm φ of eutectic solder wire (melting temperature at 183° C.) in which flux had been included at the center, were drawn at the same tension and wound at an interval of 8.5 mm in the length direction around the corners of theelastic core 1. Then, non-alkali glass filaments, each of which fiber diameter was about 9 μm, were stranded together in order to obtain a fiber bundle (yarn number: around #70), and this fiber bundle was braided by 16-yarn string manufacturing machine (using 16 yarns for manufacturing a single string), at braid coverage of about 17/25 mm, thus the space layer (glass braid) 5 was obtained. As the final step, a mixture of ethylene copolymer, serving as the insulatingcover 7, was extruded to form the cover at thickness of 0.5 mm and at extrusion temperature of 150° C., and thereafter, the cross-linking was done by applying electron beam thereto. - The thus obtained code type thermal fuse was cut at length of about 20 cm, and the insulating
cover 7 and the space layer (glass braid) 5 at each end were removed for about 1 cm respectively. Then, lead wires having the nominal cross-sectional area of 0.5 mm2, each of which was at length of 100 mm, were connected via crimp-type terminals, thus the code type thermal fuse assembly was manufactured. - Then,
Experiments - Experiment 1: Initial Operative Temperature
- Experiment Method:
- The code type thermal fuse assembly manufactured by the above method was inserted in a glass fiber braid tube at inner diameter of 4.0 mm and at length of about 15 cm, so that the code type thermal fuse part of the assembly may come to the center part of the tube. Thereafter, an electric current about 0.1 A was applied from 100 V AC power supply, by connecting incandescent bulb to the both terminals of the lead wires as an outer load. Then, the center part was heated from normal temperature, at temperature increase speed of 10° C./min. Thus, when the
conductor 3 was disconnected, the temperature was checked. - Experiment 2: Operative Temperature After Lost of Flux
- Experiment Method:
- The manufactured code type thermal fuse assembly was placed in a hot-air circulation type of constant-temperature bath at temperature of 158° C., for 384 hours, whereby the deterioration due to aging by heat was prompted, and the flux was decomposed and removed by heat. Thereafter, the code type thermal fuse assembly after heat treatment was inserted in a glass fiber braid tube at inner diameter of 4.0 mm and at length of about 15 cm, so that the code type thermal fuse part of the assembly may come to the center part of the tube. Thereafter, an electric current about 0.1 A was applied from 100 V AC power supply, by connecting incandescent bulb to the both terminals of the lead wires as an outer load. Then, the center part was heated from initial temperature of 250° C., at temperature increase speed of 10° C./min. Thus, when the
conductor 3 was disconnected, the temperature was checked. - The results of
Experiments FIG. 5 . - The tensile
resistant member 1 a, having isolated air holes, was formed by using silicone rubber to which 2 w/t parts of foaming agent (AIBN) were added. The other materials and manufacturing method were substantially the same as those of Example 1, thus the code type thermal fuse was manufactured. Then the experiments, substantially the same as those of Example 1, were done for this code type thermal fuse, of which results are also included inFIG. 5 . - As for the
conductor 3, 0.6 mm φ of eutectic solder wire without including flux was used. The other materials and manufacturing method were substantially the same as those of Example 1, thus the code type thermal fuse was manufactured. Then the experiments, substantially the same as those of Example 1, were done for this code type thermal fuse, of which results are also included inFIG. 5 . - The tensile
resistant member 1 a was prepared by a glass code having the outer diameter of about 0.7 mm, to which silicone varnishing was not applied. Thereafter, a silicone rubber, comprising a compound of 100 w/t parts of silicone rubber, 3 w/t parts of polyacetal homopolymer powder (particles passed through 100-mesh sieve) and 2 w/t parts of organic peroxide cross-linking agent kneaded on open roll, was extruded in order to cover the periphery of the tensileresistant member 1 a, so that the cross-section of the silicone rubber had six radial protrusions, of which inscribed circle was 1.6 mm and of which circumscribed circle was 1.8 mm. At the same time, hot-air vulcanization was applied, thus theelastic member 1 b was formed. The subsequent steps were substantially the same as those of Example 1, and the code type thermal fuse was manufactured. Theelastic core 1 at this stage was a silicone rubber elastic core including scattered polyacetal homopolymer powders, and there was no air hole in the inside thereof. - Then,
Experiment 1 as discussed above was done for the code type thermal fuse in this state. - Thereafter, the code type thermal fuse assembly was manufactured substantially by the same method as that of Example 1. Then, the manufactured code type thermal fuse assembly was placed in a hot-air circulation type of constant-temperature bath at temperature of 158° C., for 384 hours, whereby the deterioration due to aging by heat was prompted, thus the state after deterioration due to aging was reproduced. At this stage, the polyacetal homopolymer powder had been sublimed by heat, whereby the foamed
elastic member 1 b having isolated air holes was formed. - With reference to this Example, the code type thermal fuse in this state was heated from temperature of 300° C., at temperature increase speed of 10° C./min, and the disconnected temperature was checked as results of
Experiment 2. Then the results ofExperiment 1 andExperiment 2 were also included inFIG. 5 . - As the insulating cover, instead of using mixture of ethylene copolymer, mixture of ethylene propylene rubber was used, which was then extruded at temperature of 130° C. in order to form the cover. The other materials and manufacturing method were substantially the same as those of Example 1, thus the code type thermal fuse was manufactured. Then the experiments, substantially the same as those of Example 1, were done for this code type thermal fuse, of which results are also included in
FIG. 5 . - The elastic core was formed by using silicone rubber to which no foaming agent was added, and 0.6 mm φ of eutectic solder wire without including flux was used as the conductor. The other materials and manufacturing method were substantially the same as those of Example 1, thus the code type thermal fuse was manufactured. Then the experiments, substantially the same as those of Example 1, were done for this code type thermal fuse, of which results are also included in
FIG. 5 . - The elastic core was formed by using silicone rubber to which no foaming agent was added, and 0.6 mm φ of eutectic solder wire including flux at the center thereof was used as the conductor. The other materials and manufacturing method were substantially the same as those of Example 1, thus the code type thermal fuse was manufactured. Then the experiments, substantially the same as those of Example 1, were done for this code type thermal fuse, of which results are also included in
FIG. 5 . - According to results of
FIG. 5 , it is understood that the initial operative temperature of each Example is the melting temperature of the conductor 3 (183° C.). - With reference to the operative temperature after the lost of flux, it is understood that, as compared with the operative temperature of the conventional code type thermal fuse (Comparative Example 2), that of the code type thermal fuse according to the present embodiment, of which
elastic core 1 is comprising, the tensileresistant member 1 a, and theelastic member 1 b covering around the tensileresistant member 1 a and including the air, becomes lower. Further, with reference to Examples 2 and 4 having more isolated air holes, as compared with Examples 1 and 5, the operative temperature becomes still lower. - With reference to the code type thermal fuse of Example 3, using the
conductor 3 to which the flux application was not done, as compared with the code type thermal fuses of Examples 1, 2, 4 and 5, the operative temperature becomes higher. It is considered that, the reason will be because of larger conductor area rate of theconductor 3 as compared with that of the non-flux conductor. Similarly, it is understood that, as compared with the code type thermal fuse, the operative temperature becomes higher. - Now a second embodiment of the present invention will be explained with reference to
FIG. 3 . According to the second embodiment, with reference to the first embodiment, the space layer (glass braid) 5 has been removed. - The other structure is substantially the same as that of the first embodiment as discussed above, and the identical numerals are allotted to the identical elements, and the explanation thereof will not be made.
- With reference to the second embodiment, substantially the same experiments as those of
Experiments FIG. 5 . - According to results of
FIG. 5 , it is understood that the initial operative temperature is the melting temperature of the conductor 3 (183° C.). - With reference to the operative temperature after the lost of flux, it is understood that, as compared with the operative temperature of the conventional code type thermal fuse (Comparative Example 2, as discussed above), that of the code type thermal fuse according to the present embodiment, of which
elastic core 1 is comprising, the tensileresistant member 1 a, and theelastic member 1 b covering around the tensileresistant member 1 a and including the air, becomes lower. - Now a third embodiment of the present invention will be explained with reference to
FIG. 4 . As illustrated inFIG. 4 , a sheet type thermal fuse was manufactured, by placing the code type thermal fuse according to the first embodiment as discussed above, in a serpentine manner by any method such as that disclosed in Japanese Unexamined Patent Publication No. Sho 62-44394.Reference numeral 21 shows a double-faced adhesive paper, having a peelingpaper 23 on one side.Reference numeral 25 shows the sheet type thermal fuse, positioned in a serpentine manner on the upper surface of the double-facedadhesive paper 21. Further,reference numeral 27 shows a metal foil covering the whole part of the sheet typethermal fuse 25, and themetal foil 27 has been adhered to and fixed on the double-facedadhesive paper 21. - An acrylic adhesive paper is used as the double-faced
adhesive paper 21, and an aluminum foil at thickness of 100 μ m is used as themetal foil 27. - Since the present embodiment was provided according to Japanese Unexamined Patent Publication No. Sho 62-44394, the
metal foil 27 and the double-facedadhesive paper 21 are used. However, it is possible to manufacture by not referring to this Unexamined Patent Publication, or it is also possible to use other material, such as a plastic film instead of the metal foil. - The thus manufactured sheet type thermal fuse was attached to an iron panel at thickness of 0.5 mm, and the panel was placed in upright position. A commercially available wall paper was attached to the reverse side of the panel. In this state, 0.5 A of electric current was applied to the sheet type thermal fuse, and a burner was moved closer so that the burner flame was in contact with the panel. This state was maintained until the conductor of the thermal fuse was disconnected. Thereafter, the sheet type thermal fuse detected the heat, and was disconnected. After disconnection, there was no change, such as carbonization of the wall paper on the reverse side of the panel, and it was found that the thermal fuse expressed the effective performance.
- Now a fourth embodiment of the present invention will be explained with reference to
FIGS. 6 and 7 . According to the present embodiment, an insulatingcore member 101 has a tensileresistant member 101 a at the center, around which is covered by a polymerelastic member 101 b including the air. Aconductor 3 is wound around the insulatingcore member 101. Thus, the insulatingcore member 101 and theconductor 3 serve as afuse core 105. Further, thefuse core 105 is covered by an insulatingcover 107. The insulatingcover 107 has at least one or more (in the present embodiment, six)protrusions 109, formed continuously or intermittently on the inner surface in the length direction. - The insulating
core member 101 is formed by any material, having characteristic of being not melted around the melting temperature of theconductor 103, and also characteristic of expanding in the circumferential direction, for example, any metal wire to which insulation process has been applied, such as an electric wire in which thermoplastic polymer or thermoset polymer has been extruded on a conductor, or cable material comprising any polymer which has been formed by plastic extrusion of synthetic fiber, thermoplastic polymer or thermoset polymer, or any inorganic material such as ceramic fiber or glass fiber. Any one of the above materials may be used as a single material, but it is also possible to use a plurality of materials by applying the same tension thereto, or by stranding together, or by preparing composite material through combination of different material types. - As discussed above, among these materials according to the present embodiment, with reference to the structure in which the tensile
resistant member 101 a at the center is covered by the polymerelastic member 101 b including the air, it is possible to reinforce the mechanical strength appropriately, and at the same time, it is also possible to arbitrarily control the degree of expansion of the polymerelastic member 101 b including the air. - The tensile
resistant member 101 a may be used for the purpose of improving the tensile strength and flexibility of the code type thermal fuse obtained by the present embodiment. The tensileresistant material 101 a may be formed by using any known textile material. - The polymer
elastic member 101 b including the air as discussed has the structure that delomorphous or amorphous airtight spaces have been formed, preferably at least any part in the inside of the elastic material comprising ordinary elastomer material, for example, silicone rubber, ethylene propylene rubber, natural rubber, isoprene rubber, acrylic rubber, fluorocarbon rubber, ethylene-vinyl acetate copolymer (EVA), ethylene-ethyl acrylate copolymer resin (EEA), or any thermoplastic elastomer (TPE). It is possible to use, for example, foamed elastic material having isolated air holes, partially foamed elastic material, or elastic material having continuous holes in the length direction so that the airtight spaces may be formed in the post-process. - The
elastic member 101 b as discussed above may be formed by any known method. There are various methods, for example, such as that the elastomer material serving as the elastic member has been mixed with organic foaming agent or inorganic foaming agent, and the mixture is heated and thus foamed, whereby the foamed elastic member having isolated air holes can be formed. Further, it is also possible to use other methods, such as forming of foamed elastic member by including gas during extrusion molding of elastomer material, or forming of partially foamed elastic member by adding sublimation material powder through heat-aging to elastomer material, or forming of the airtight spaces, by preliminarily preparing elastic member having continuous holes in the length direction during contour extrusion of elastomer material, and in the post-process, by closing the continuous holes in the length direction through use of winding tension of the conductor, which will be explained afterwards. - As for the
conductor 103, it is possible to use, for example, metal thin wire selected from the group of low-melting point alloys and solder, or wire formed from conductive resin manufactured by filling high-density metal powder, metal oxide or carbon black, into thermoplastic resin such as olefin resin or polyamide resin. The preferable wire diameter of theconductor 103 is substantially from 0.04 mm to 2.0 mm, because an ordinary winding machine can wind such aconductor 103 around the elastic core in the length direction. - The
conductor 103 has been wound around the insulatingcore member 101 by applying tension, so that theconductor 103 may not at least be loose, thus thefuse core 105 is prepared. It is more preferable to select the polymerelastic member 101 b including the air as the insulatingcore member 101, because theconductor 103 may dig into the insulatingcore member 101 sufficiently. The each interval of winding theconductor 103 is, preferably, not less than one and half of the wire diameter, and more preferably, not less than twice and not more than 15 times. It is also possible to provide collective winding in the length direction by winding the paralleledconductors 3 or by winding the strandedconductors 103. - The thus obtained
fuse core 105 is covered by the insulatingcover 107, whereby the code type thermal fuse according to the present embodiment is completed. As discussed above, according to the present embodiment, the insulatingcover 107 has at least one or more (in the present embodiment, six)protrusions 109, formed continuously or intermittently on the inner surface in the length direction. Theprotrusions 109 have been provided because of the following reason. - This is because, when the insulating
core member 101 is heated by any abnormal state and expanded in the circumferential direction, theconductor 103 wound around the insulatingcore member 101 is pressed between the insulatingcore member 101 and theprotrusions 109 provided on the inner periphery of the insulatingcover 107, whereby theconductor 103 may be disconnected more surely by pressure during melting or just before melting thereof. - The
protrusions 109 have further merits. As a predetermined space may be formed between thefuse core 105 and the insulatingcover 107, after theconductor 103 is disconnected by detecting abnormal temperature, it is possible to prevent re-connection of theconductor 3 by re-heating more effectively. - As there are various known methods in regard to the insulating
cover 107, it is possible to select any appropriate method from them, which can be worked at lower temperature than the melting temperature of theconductor 103. It is possible to use the method, for example, in which a thermoplastic polymer such as ethylene copolymer workable at relatively low temperature, or a synthetic rubber such as ethylene propylene rubber, styrene butadiene rubber, isoprene rubber or nitrile rubber, is cross-linked by using low-temperature cross-linking method such as radiation cross-linking. Further, it is also possible to use a forming method by using silicone rubber which can be extruded around normal temperature and which can be cross-linked at relatively low temperature. In particular, when the silicone rubber is used, it is also possible to provide a braid as exterior element in order to reinforce the mechanical strength of the insulatingcover 107. The insulatingcover 107 may be provided, not only by the extrusion method as discussed above, but also by first forming a tubular insulatingcover 107 separately, and thereafter, by inserting thefuse core 105. The insulatingcover 107 may be preferably thin, because of the increasing heat sensitivity, as long as the required characteristics such as the electric insulation ability and mechanical strength are satisfied. It is preferable that the size of eachprotrusion 109 protruding in the circumferential direction is smaller because of the increasing heat sensitivity, as long as the required characteristic in order to prevent the re-connection is satisfied. - According to the present embodiment, when the temperature increases, the insulating
core member 101 is expanded in the circumferential direction, and presses theconductor 103 toward theprotrusions 109 on the inner periphery of the insulatingcover 107, whereby theconductor 103 may be disconnected more surely during melting or just before melting thereof. Thus, even when the original function of flux (the function to improve the detecting accuracy) is deteriorated, it is still possible to maintain the good disconnection time. Further, it is still effective even when any deterioration, such as forming of oxide, appears on the surface of theconductor 103 due to long-term use thereof and the melting disconnection cannot be done easily. As the structure of parts is not changed from conventional structure, and no complicated structure is required. Thus, it is possible to provide cost-effective products. - Now several examples according to the present embodiment will be explained.
- First, silicone varnishing was applied to a glass code having the outer diameter of about 0.7 mm, thus the tensile
resistant member 101 a was provided. Thereafter, a silicone rubber, comprising a compound of 100 w/t parts of silicone rubber, 1 w/t part of foaming agent (AIBN) and 2 w/t parts of organic peroxide cross-linking agent kneaded on open roll, was extruded in order to cover the periphery of the tensileresistant member 101 a, so that the cross-section of the outer diameter was 1.8 mm. At the same time, the silicone rubber was foamed by applying hot-air vulcanization. Thus, the insulatingcore member 101 was formed. - Thereafter, two
parallel conductors 103, respectively comprising 0.5 mm φ of non-lead solder wire (tin-copper alloy, melting temperature at 217° C.) in which flux had been included at the center, were drawn at the same tension and wound at winding pitch of 5 times/10 mm (4 times the wire diameter) in the length direction around the insulatingcore member 101. As the final step, a mixture of ethylene copolymer serving as the insulatingcover 107 was extruded at temperature of 150° C., so that the sixprotrusions 109, of which respective width was 0.6 mm and height was 0.3 mm, and of which thickness was 0.3 mm, were provided. Thereafter, the cross-linking was done by applying electron beam thereto. - The thus obtained code type thermal fuse was cut at length of about 20 cm, and each end of the insulating
cover 107 was removed for about 1 cm. Then, lead wires having the nominal cross-sectional area of 0.5 mm2, each of which was at length of 100 mm, were connected via crimp-type terminals, thus the code type thermal fuse assembly was manufactured. - Then,
Experiments FIG. 7 . - The outer diameter of the insulating
core member 101 was changed from 1.8 mm to 2.2 mm. The other manufacturing method was substantially the same as that of Example 7, thus the code type thermal fuse was manufactured. Then the experiments, substantially the same as those of Examples 1 and 2, were done for this code type thermal fuse, of which results are also included inFIG. 7 . - The outer diameter of the insulating
core member 101 was changed from 1.8 mm to 2.2 mm, and the height of eachprotrusion 109 was also changed from 0.3 mm to 0.5 mm. The other manufacturing method was substantially the same as that of Example 7, thus the code type thermal fuse was manufactured. Then the experiments, substantially the same as those of Examples 1 and 2, were done for this code type thermal fuse, of which results are also included inFIG. 7 . - There was no protrusion on the inner surface of the insulating
cover 107. The other manufacturing method was substantially the same as that of Example 7, thus the code type thermal fuse was manufactured. Then the experiments, substantially the same as those of Examples 1 and 2, were done for this code type thermal fuse, of which results are also included inFIG. 7 . - According to results of
FIG. 7 , it is understood that the initial operative temperature of each Example is the melting temperature of the conductor (217° C.). - With reference to the operative temperature after the lost of flux, it is understood that the operative temperature of the code type thermal fuse according to Examples 7 through 9 becomes lower, in which the insulating
core member 101, comprising the material having characteristic of expanding in the circumferential direction, is combined with the insulatingcover 107 having theprotrusions 109 on the inner surface. In particular, according to Example 8 in which the outer diameter of the insulatingcore member 101 was enlarged, the operative temperature was the lowest. This is because the space between the insulatingcore member 101 and theprotrusions 109 becomes narrower, and because the pressure against theconductor 103 becomes larger due to increase of expanding volume of the insulatingcore member 101. Further, with reference to Example 9 in which the height of theprotrusions 109 was larger, the operative temperature was good, but as compared with Examples 7 and 8, the operative temperature was rather higher. This is because, as theprotrusions 109 became larger, it became more difficult to transfer the heat from the outside to theconductor 103 correspondingly, thus the heat sensitivity became poor. On the other hand, with reference to the code type thermal fuse according to Example 10 in which there was noprotrusion 109 on the inner surface of the insulatingcover 107, the operative temperature became relatively higher. This is because, as there was noprotrusion 109, it was difficult to apply pressure, generated by expansion of the insulatingcore member 101, to theconductor 103. - Now a fifth embodiment of the present invention will be explained with reference to
FIGS. 8 and 9 . There is an insulatingcore member 201, comprising a tensileresistant member 201 a and acover member 201 b. The tensileresistant member 201 a was provided by applying silicone varnishing to a glass code having the outer diameter of about 0.7 mm. Further, a compound of 100 w/t parts of silicone rubber, 1 w/t part of foaming agent (AIBN) and 2 w/t parts of organic peroxide cross-linking agent kneaded on open roll, is used for thecover member 201 b. Then, thecover member 201 b is extruded in order to cover the periphery of the tensileresistant member 201 a, so that the cross-section of the outer diameter is 1.8 mm. At the same time, the silicone rubber is foamed by applying hot-air vulcanization. Thus, the insulatingcore member 201 is formed. - There are two
parallel conductors 203 wound around the outer periphery of the insulatingcore member 201 in the length direction. Eachconductor 203 comprises 0.5 mm φ of non-lead solder wire (tin-copper alloy, melting temperature at 217° C.) in which flux had been included at the center, and two of which are drawn at the same tension and wound at winding pitch of 5 times/10 mm (4 times the wire diameter) in the length direction around the insulatingcore member 201, so that theconductors 203 may dig into the insulatingcore member 201 sufficiently. - There is a
fuse core 207, comprising a line-shapedinsulator 205 wound around the outer periphery of theconductor 203 in the length direction. As for the line-shapedinsulator 205, a monofilament of 0.4 mm φ polyphenylene sulfide is used, and the line-shapedinsulator 205 is wound in the length direction, reverse to that of theconductor 203, at winding pitch of 10 times/32 mm (8 times the wire diameter). - The outer periphery of the thus obtained
fuse core 207 is covered by tubular insulatingcover 209. As for the insulatingcover 209, a mixture of ethylene copolymer serving has been extruded at temperature of 150° C., in a tubular shape having the thickness of 0.3 mm and the outer diameter of 4.2 mm. Thereafter, the cross-linking is done by applying electron beam thereto, thus the code type thermal fuse according to the present embodiment is obtained. - The insulating
core member 201 is formed by any material, having characteristic of being not melted around the melting temperature of theconductor 203, and also characteristic of expanding in the circumferential direction, for example, any metal wire to which insulation process has been applied, such as an electric wire in which thermoplastic polymer or thermoset polymer has been extruded on a conductor, or cable material comprising any polymer which has been formed by plastic extrusion of synthetic fiber, thermoplastic polymer or thermoset polymer, or any inorganic material such as ceramic fiber or glass fiber. Any one of the above materials may be used as a single material, but it is also possible to use a plurality of materials by winding theparallel conductors 3, or by stranding together, or by preparing composite material through combination of different material types. - As discussed above, among these materials according to the present embodiment, with reference to the structure in which the tensile
resistant member 201 a at the center is covered by polymer material including the air serving as thecover member 201 b, it is possible to improve the tensile strength and flexibility, and at the same time, it is also possible to arbitrarily control the degree of expansion of thecover member 201 b. Thus, this structure is particularly preferable among others. - The tensile
resistant material 201 a may be formed by using any known textile material. Further, a polymer material including the air, serving as thecover member 201 b, may have the structure that delomorphous or amorphous airtight spaces have been formed, preferably at least any part in the inside of polymer material comprising such as elastomer. There are various forming methods, for example, such as that polymer material has been mixed with organic foaming agent or inorganic foaming agent, and the mixture is heated and thus foamed, whereby the material having isolated air holes can be formed. Further, it is also possible to use other forming methods, such as by including gas during extrusion molding of polymer material, or forming of partially foamed material by adding sublimation material powder through heat-aging to polymer material, or forming of the airtight spaces, by preliminarily preparing polymer member having continuous holes in the length direction, and in the post-process, by closing the continuous holes in the length direction. As for the polymer material as discussed above, it is possible to use any ordinary elastomer material, for example, silicone rubber, ethylene propylene rubber, natural rubber, isoprene rubber, acrylic rubber, fluorocarbon rubber, ethylene-vinyl acetate copolymer (EVA), ethylene-ethyl acrylate copolymer resin (EEA), or any thermoplastic elastomer (TPE). - As for the
conductor 203, it is possible to use, for example, metal thin wire selected from the group of low-melting point alloys and solder, or wire formed from conductive resin manufactured by filling high-density metal powder, metal oxide or carbon black, into thermoplastic resin such as olefin resin or polyamide resin. The preferable wire diameter of theconductor 203 is substantially from 0.4 mm to 2.0 mm, because an ordinary winding machine can wind such aconductor 203 around the insulatingcore member 201 in the length direction. Theconductor 203 may be prepared by using a single conductor, or by using a plurality of paralleled materials through application of the same tension thereto, or by using a plurality of stranded materials. - The line-shaped
insulator 205 is formed by any material, having characteristic of being not melted at the melting temperature of theconductor 203, for example, a wire material comprising any polymer material in which synthetic fiber, thermoplastic polymer or thermoset polymer, such as aliphatic polyamide, aramid, polyethylene terephthalate, wholly aromatic polyester or novoloid has been formed by plastic extrusion, or a wire material comprising any inorganic material such as ceramic fiber or glass fiber. Any one of the above materials may be used as a single material, but it is also possible to use a plurality of materials by applying the same tension thereto, or by stranding together, or by preparing composite material through combination of different material types. - It is also possible to provide the line-shaped
insulator 205 having characteristic of contracting in the length direction around the melting temperature of theconductor 203. Accordingly, the line-shapedinsulator 205 may squeeze theconductor 203, whereby the disconnection of theconductor 203 may be done more securely. As for the line-shapedinsulator 205 having characteristic of contracting in the length direction, it is possible to use, for example, any synthetic fiber such as aliphatic polyamide, aramid, polyethylene terephthalate or polybutylene terephthalate, or any fiber formed by high drawing of any of these synthetic fibers, or any thermoplastic resin such as polyethylene, polypropylene, aliphatic polyamide, polyethylene terephthalate, propylene fluoroethylene, vinylidene fluoride or ethylene-tetrafluoroethylene copolymer, which has been extruded in the shape of wire and drawn thereafter, or a wire material which has been formed by annealing of synthetic resin, such as polyacetal, of which contracting rate is relatively large. - It is also possible to provide the line-shaped
insulator 205 having characteristic of expanding in the circumferential direction around the melting temperature of theconductor 203. Accordingly, the insulatingcore member 201 is expanded in the circumferential direction and presses theconductor 203 against the line-shapedinsulator 205, and at the same time, the line-shapedinsulator 205 is also expanded and presses theconductor 203 against the insulatingcore member 201, and these characteristics are preferable because the disconnection of theconductor 203 may be done more securely. As for the line-shapedinsulator 205 having characteristic of expanding in the circumferential direction, it is possible to use any material of which positive expansion coefficient is large, for example, foamed cross-linked rubber, or cross-linked rubber including any foaming material such as ADCA, exfoliated graphite or low-boiling liquid contained in micro capsule, or cross-linked rubber formed by knealing and incorporating relatively low-boiling organic solvent in rubber, and after extrusion, formed by vaporizing the incorporated organic solvent by heat, or any material which has been formed by blowing a high-compression gas at the same time of extrusion molding of a synthetic resin, or a cross-linked rubber, which has been formed by adding heat sublimation material powder to an elastomer material, and thereafter, by heat sublimation of the added powder, or a cross-linked rubber, which has been formed by preliminarily preparing elastic member having continuous holes in the length direction during contour extrusion of elastomer material, and in the post-process, by closing the continuous holes in the length direction at predetermined intervals through use of winding tension of the conductor, which will be explained afterwards. - As there are various known materials and methods in regard to the insulating
cover 209, it is possible to select any appropriate material and method from them, which can realize the working temperature lower than the melting temperature of theconductor 203. It is possible to use the method, for example, in which a thermoplastic polymer such as ethylene copolymer workable at relatively low temperature, or a synthetic rubber such as ethylene propylene rubber, styrene butadiene rubber, isoprene rubber or nitrile rubber, is cross-linked by using low-temperature cross-linking method such as radiation cross-linking. Further, it is also possible to use a forming method by using silicone rubber which can be extruded around normal temperature and which can be cross-linked at relatively low temperature. In particular, when the silicone rubber is used, it is also possible to provide a braid as exterior element in order to reinforce the mechanical strength of the insulatingcover 209. The insulatingcover 209 may be preferably thin, because of the increasing heat sensitivity, as long as the required characteristics such as the electric insulation ability and mechanical strength are satisfied. - The materials and numeric values as discussed above are mere examples of the embodiment, and it is possible to determine appropriately, according to using application, using purpose, using environment, etc.
- Now a sixth embodiment of the present invention will be explained with reference to
FIG. 10 . There is aconductor 303, substantially the same as that of the fifth embodiment as discussed above, around which a line-shapedinsulator 305, also substantially the same as that of the fifth embodiment, is wound in the length direction at winding pitch of 10 times/16 mm (4 times the wire diameter). - Thereafter, the
conductor 303, around which the line-shapedinsulator 305 has been wound in the length direction, is also wound around an insulatingcore member 301, substantially the same as that of the fifth embodiment, at winding pitch of 10 times/85 mm (6.5 times the wire diameter), thus afuse core 307 is obtained. There is a tubular insulatingcover 309 covering the outer periphery of thefuse core 307. The material of the insulatingcover 309 is substantially the same as that of the fifth embodiment. Accordingly, a code type thermal fuse according to the present embodiment is obtained. - Now a seventh embodiment of the present invention will be explained with reference to
FIG. 11 . There is an insulatingcore member 401, formed from a compound of 100 w/t parts of silicone rubber, 1 w/t part of foaming agent (AIBN) and 2 w/t parts of organic peroxide cross-linking agent kneaded on open roll. Then, this material for manufacturing the insulatingcore member 401 is extruded, so that the cross-section of the outer diameter is 1.2 mm. At the same time, the silicone rubber is foamed by applying hot-air vulcanization. Thus, the insulatingcore member 401 is formed. - Thereafter, the insulating
core member 401, aconductor 403 and a line-shapedinsulator 405, both substantially the same as those of the fifth embodiment, are stranded together at pitch of 3.0 mm, thus afuse core 407 is obtained. - There is a tubular insulating
cover 409 covering the outer periphery of thefuse core 407. The material of the insulatingcover 409 is substantially the same as that of the fifth embodiment. Accordingly, a code type thermal fuse according to the present embodiment is obtained. - Now an eighth embodiment of the present invention will be explained with reference to
FIG. 12 . According to the eighth embodiment, there is abraid 505, substantially serving as the line-shaped insulator of the fifth embodiment. The other structure is substantially the same as that of the fifth embodiment as discussed above, and the identical numerals are allotted to the identical elements, and the explanation thereof will not be made. - The fifth through eighth embodiments as discussed above have the following merits. First, as the insulating
core members conductors insulators braid 505. Accordingly, theconductors conductors - As the
conductors covers conductors conductors conductors conductors - With reference to the fifth embodiment, there is an example, that the
conductor 203 is wound around the insulatingcore member 201 in the length direction, and that the other line-shapedinsulator 205 is wound in the length direction reverse to that of theconductor 203. It is also possible, for example, to use a plurality of the line-shapedinsulators 205. Further, it is also possible to wind the line-shapedinsulator 205 and theconductor 203 in the same length direction, as long as the winding pitch of the line-shapedinsulator 205 is different from that of theconductor 203. It is also possible to add the line-shapedinsulator 205 directly along the longitudinal direction. - As for the
conductor 203, for example, it is also possible to add theconductor 203 to the insulatingcore member 201 directly along the longitudinal direction. - With reference to the sixth embodiment as discussed above, the explanation is made as for an example of winding a single line-shaped
insulator 305 around theconductor 303 in the length direction, and then winding this unit around the insulatingcore member 301 in the length direction. However, it is also possible, for example, to use a plurality of line-shapedinsulators 305, or to use a braid thereof, and it is also possible to use theconductor 303 and the line-shapedinsulator 305 stranded together. Further, it is also possible to wind theconductor 303 around the line-shapedinsulator 305 in the length direction. It is also possible to wind the line-shapedinsulator 305 around theconductor 303 in the length direction, and to add it to the insulatingcore member 301 directly along the longitudinal direction. - According to the fifth and six embodiments as discussed above, the explanations are made as for examples of winding the
conductors insulators core members core member 401, theconductor 403 and the line-shapedinsulator 405 together. It is also possible, for example, to use theconductor 203 wound around the insulatingcore member 205 in the length direction, or to use the insulatingcore member 201 and theconductor 203 stranded together in advance. - As discussed above, it is possible to provide various examples, but each example is essentially characterized in that, as illustrated in
FIG. 9 , at least a part of the fuse core 207 (307, 407) in the length direction has the structure that the conductor 203 (303, 403) is sandwiched between the insulating core member 201 (301, 401) and the line-shaped insulator 205 (305, 405 or the braid 505). - In this connection, the characteristic evaluation test was done for Example 11 corresponding to the fifth embodiment, Example 12 corresponding to the sixth embodiment, and Examples 13 and 14 corresponding to the seventh embodiment, of which explanation will be done as follows.
- For reference, according to Example 14, the line-shaped
insulator 205 was not used in regard to the fifth embodiment. - First, each of the code type thermal fuses according to Examples 11 through 14 was cut at length of about 20 cm, and each end of the insulating cover was removed for about 1 cm. Then, lead wires having the nominal cross-sectional area of 0.5 mm2, each of which was at length of 100 mm, were connected via crimp-type terminals, thus the code type thermal fuse assembly was manufactured.
- Then,
Experiments FIG. 13 . - According to the results of
FIG. 13 , it was confirmed that, in regard to Examples 11 through 13, as compared with Example 14 in which the line-shaped insulator was not used, the operative temperature became lower, because of combination of the insulating core member, comprising the material having characteristic of expanding in the circumferential direction, with the line-shaped insulator. - Now a ninth embodiment of the present invention will be explained with reference to
FIG. 14 . According to the ninth embodiment, together with the expansion of an insulating core member, an insulating cover is contracted, whereby a conductor is disconnected, of which explanation will be done as follows. - There is an
elastic core 601 including the air, and theelastic core 601 has a tensileresistant member 601 a at the center, around which is covered by anelastic member 601 b including the air. Aconductor 603 is wound around theelastic core 601, and an insulatingcover 607 is wound around theconductor 603. Thus, theelastic core 601 and theconductor 603 serve as afuse core 609. Further, the insulatingcover 607 has at least one or more (in the present embodiment, six)protrusions 611, formed continuously or intermittently on the inner surface in the length direction. - The insulating
cover 607 has characteristic of contracting in the inward circumferential direction, and the material thereof is not limited, as long as the material belongs to pyrolysis polymer, and a plurality of material types may also be mixed with each other. It is possible to use, for example, any resin material such as polyester resin, polyamide resin, polyolefin resin (ethylene copolymer) or fluorocarbon resin, or any elastomer material such as nitrile rubber, ethylene propylene rubber, chloroprene rubber, acrylic rubber, silicone rubber or fluorocarbon rubber. According to the present embodiment, a mixture of ethylene propylene rubber with polyolefin resin (ethylene copolymer) at the mixing rate of 1:1 has been prepared, with which additives such as fire retardant, antioxidant, lubricant, cross-linking aids, etc., have been further mixed. - The contracting speed of the insulating
cover 607 can be adjusted by pyrolysis temperature. When the pyrolysis temperature is high (i.e. when the mixture has much material having high pyrolysis temperature), the contracting speed will become lower. On the other hand, when the pyrolysis temperature is low (i.e. when the mixture has much material having low pyrolysis temperature), the contracting speed will become higher. Therefore, it is possible to determine the speed appropriately according to the using condition. - The other structure is substantially the same as that of the fourth embodiment as discussed above, and the identical numerals are allotted to the identical elements, and the explanation thereof will not be made.
- Now a tenth embodiment of the present invention will be explained with reference to
FIG. 15 . According to the tenth embodiment, with reference to the ninth embodiment as discussed above, aspace layer 605 comprising a glass braid is provided on the outer peripheral side of theconductor 603. The other structure is substantially the same as that of the ninth embodiment as discussed above, and the identical numerals are allotted to the identical elements, and the explanation thereof will not be made. - In this connection, the characteristic evaluation test was done for Examples 15, 16 and 17 corresponding to the ninth embodiment, and Example 18 corresponding to the tenth embodiment, of which explanation will be done as follows. The structure of each Example is substantially the same as that of Example 7 corresponding to the fourth embodiment as discussed above, except for the insulating
cover 607 of Example 15. - According to Example 16, with reference to Example 15, the
elastic member 601 b was not kneaded with foaming agent (AIBN), whereby theconductor 603 was disconnected only by contracting of the insulatingcover 607. - Further, according to Example 17, with reference to Example 15, an eutectic solder wire (melting temperature at 183° C.) at diameter of 0.6 mm was used as the
conductor 603. - First, each of the code type thermal fuses according to Examples 15 through 18 was cut at length of about 20 cm, and each end of the insulating cover was removed for about 1 cm. Then, lead wires having the nominal cross-sectional area of 0.5 mm2, each of which was at length of 100 mm, were connected via crimp-type terminals, thus the code type thermal fuse assembly was manufactured.
- Then,
Experiments Experiment 3 as discussed below was also done respectively, of which results are shown inFIG. 16 . - Experiment 3: Constant Temperature Heating After Lost of Flux
- Experiment Method:
- As for the thus manufacture code type thermal fuse, flux was removed likewise the case of
Experiment 2. Thereafter, the temperature was maintained at 260° C., 280° C. and 300° C., respectively, and the time until disconnection was measured. - According to the results of
FIG. 16 , it is confirmed that, with reference to the code type thermal fuse of the present embodiment, by maintaining theelastic core 601 for a long time at a temperature (260° C.-300° C.) not higher than the operative temperature of theelastic core 601, the insulatingcover 607 is contracted, whereby theconductor 603 is disconnected. When theelastic core 601 is maintained relatively at higher temperature (260° C.-300° C.) which is not higher than the operative temperature of theelastic core 601, the expanding motion of theelastic core 601 will not be facilitated, which would prevent disconnection of theconductor 603. Therefore, it is confirmed that the contracting motion of the insulatingcover 607 is considerably effective. - According to the ninth and tenth embodiments as discussed above, the protrusions are provided on the inner periphery of the insulating
cover 607. However, it is possible to provide the insulatingcover 607 without having the protrusion. - The present invention relates to the code type thermal fuse and a sheet type thermal fuse, which can be disconnected when any part thereof is exposed in an abnormal high temperature state, so that the abnormal temperature can be detected. More particularly, the present invention relates to the code type thermal fuse and the sheet type thermal fuse, of which disconnection time is still good even after being deteriorated due to aging by heat, and which has good operative reliability. The present invention may be used for various purposes, for example, refrigerators, indoor and outdoor equipment of air conditioners, cloth drying machines, rice cookers with keep-warm function, hot plates, coffee brewers, water heaters, ceramic heaters, oil heaters, automatic dispensers, electric blankets, floor heating panels, copying machines, facsimile machines, dishwashers, fryers, etc.
Claims (20)
1. A code type thermal fuse comprising:
a fuse core produced by winding a conductor meltable at a predetermined temperature on an insulating core member continuously provided in the length direction; and
an insulating cover covering the outer periphery of said fuse core, characterized in that:
said conductor can be cut by expanding said insulating core member at a predetermined temperature and/or by contracting said insulating cover at said predetermined temperature.
2. The code type thermal fuse as claimed in claim 1 , further characterized in that:
said insulating core member has at least one or more protrusions formed continuously or intermittently in the length direction on the outer periphery of said insulating core member.
3. The code type thermal fuse as claimed in claim 1 , further characterized in that:
said insulating cover has at least one or more protrusions formed continuously or intermittently in the length direction on the inner periphery of said insulating cover.
4. The code type thermal fuse as claimed in claim 1 , further characterized in that:
another line-shaped or braid-shaped insulator is provided on the inner peripheral side of said insulating cover; and
said conductor is sandwiched between said insulating core member and said line-shaped or braid-shaped insulator at least partially in the length direction of said conductor.
5. The code type thermal fuse as claimed in claim 4 , further characterized in that:
said line-shaped or braid-shaped insulator has a characteristic of contracting in the length direction around a melting temperature of said conductor.
6. The code type thermal fuse as claimed in claim 4 , further characterized in that:
said line-shaped or braid-shaped insulator has a characteristic of expanding in the peripheral direction around a melting temperature of said conductor.
7. The code type thermal fuse as claimed in claim 1 , further characterized in that:
said insulating core member comprises a gas-containing material as a structural element.
8. The code type thermal fuse as claimed in claim 7 , further characterized in that:
said insulating core member comprises a gas-containing material covering a periphery of a tensile resistant member at the center of said insulating core member.
9. A sheet type thermal fuse, comprising:
the code type thermal fuse according to claim 1 , provided on a flat surface in a serpentine manner; and
means for fixing a layout of said code type thermal fuse.
10. The code type thermal fuse as claimed in claim 2 , further characterized in that:
said insulating cover has at least one or more protrusions formed continuously or intermittently in the length direction on the inner periphery of said insulating cover.
11. The code type thermal fuse as claimed in claim 2 , further characterized in that:
said insulating core member comprises a gas-containing material as a structural element.
12. The code type thermal fuse as claimed in claim 3 , further characterized in that:
said insulating core member comprises a gas-containing material as a structural element.
13. The code type thermal fuse as claimed in claim 4 , further characterized in that:
said insulating core member comprises a gas-containing material as a structural element.
14. The code type thermal fuse as claimed in claim 5 , further characterized in that:
said insulating core member comprises a gas-containing material as a structural element.
15. The code type thermal fuse as claimed in claim 6 , further characterized in that:
said insulating core member comprises a gas-containing material as a structural element.
16. A sheet type thermal fuse, comprising:
the code type thermal fuse according to claim 2 , provided on a flat surface in a serpentine manner; and
means for fixing a layout of said code type thermal fuse.
17. A sheet type thermal fuse, comprising:
the code type thermal fuse according to claim 3 , provided on a flat surface in a serpentine manner; and
means for fixing a layout of said code type thermal fuse.
18. A sheet type thermal fuse, comprising:
the code type thermal fuse according to claim 4 , provided on a flat surface in a serpentine manner; and
means for fixing a layout of said code type thermal fuse.
19. A sheet type thermal fuse, comprising:
the code type thermal fuse according to claim 5 , provided on a flat surface in a serpentine manner; and
means for fixing a layout of said code type thermal fuse.
20. A sheet type thermal fuse, comprising:
the code type thermal fuse according to claim 6 , provided on a flat surface in a serpentine manner; and
means for fixing a layout of said code type thermal fuse.
Applications Claiming Priority (5)
Application Number | Priority Date | Filing Date | Title |
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JP2002263959 | 2002-09-10 | ||
JP2002-263959 | 2002-09-10 | ||
JP2002-371175 | 2002-12-24 | ||
JP2002371175 | 2002-12-24 | ||
PCT/JP2003/007516 WO2004025679A1 (en) | 2002-09-10 | 2003-06-13 | Code-shaped temperature fuse and sheet-shaped temperature fuse |
Publications (2)
Publication Number | Publication Date |
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US20050258928A1 true US20050258928A1 (en) | 2005-11-24 |
US7439844B2 US7439844B2 (en) | 2008-10-21 |
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Application Number | Title | Priority Date | Filing Date |
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US10/526,980 Expired - Fee Related US7439844B2 (en) | 2002-09-10 | 2003-06-13 | Cord type thermal fuse and sheet type thermal fuse |
Country Status (5)
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US (1) | US7439844B2 (en) |
JP (1) | JP4342443B2 (en) |
CN (1) | CN100367432C (en) |
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WO (1) | WO2004025679A1 (en) |
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US20120299692A1 (en) * | 2007-10-09 | 2012-11-29 | Littelfuse, Inc. | Fuse providing overcurrent and thermal protection |
US20140345906A1 (en) * | 2009-07-16 | 2014-11-27 | 3M Innovatives Properties Company | Insulated composite power cable and method of making and using same |
US11248674B2 (en) * | 2017-08-24 | 2022-02-15 | Ressorts Liberte Inc. | Coil spring and method of fabrication thereof |
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US20100033295A1 (en) | 2008-08-05 | 2010-02-11 | Therm-O-Disc, Incorporated | High temperature thermal cutoff device |
US9117615B2 (en) | 2010-05-17 | 2015-08-25 | Littlefuse, Inc. | Double wound fusible element and associated fuse |
JP5874384B2 (en) * | 2011-01-07 | 2016-03-02 | 日立金属株式会社 | cable |
CN103515041B (en) | 2012-06-15 | 2018-11-27 | 热敏碟公司 | High thermal stability pellet composition and its preparation method and application for hot stopper |
JP6146338B2 (en) * | 2014-02-25 | 2017-06-14 | 日立金属株式会社 | Electric wire / cable manufacturing method |
EP3989256A1 (en) * | 2020-10-21 | 2022-04-27 | SolarEdge Technologies Ltd. | Thermal fuse |
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- 2003-06-13 US US10/526,980 patent/US7439844B2/en not_active Expired - Fee Related
- 2003-06-13 WO PCT/JP2003/007516 patent/WO2004025679A1/en active Application Filing
- 2003-06-13 AU AU2003242356A patent/AU2003242356A1/en not_active Abandoned
- 2003-06-13 CN CNB038211874A patent/CN100367432C/en not_active Expired - Fee Related
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Cited By (8)
Publication number | Priority date | Publication date | Assignee | Title |
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US20120299692A1 (en) * | 2007-10-09 | 2012-11-29 | Littelfuse, Inc. | Fuse providing overcurrent and thermal protection |
US9443688B2 (en) * | 2007-10-09 | 2016-09-13 | Littelfuse, Inc. | Fuse providing overcurrent and thermal protection |
US20140345906A1 (en) * | 2009-07-16 | 2014-11-27 | 3M Innovatives Properties Company | Insulated composite power cable and method of making and using same |
US9093194B2 (en) * | 2009-07-16 | 2015-07-28 | 3M Innovative Properties Company | Insulated composite power cable and method of making and using same |
US20150325337A1 (en) * | 2009-07-16 | 2015-11-12 | 3M Innovative Properties Company | Insulated composite power cable and method of making and using same |
WO2012012442A1 (en) * | 2010-07-20 | 2012-01-26 | Cooper Technologies Company | Fuse link auxiliary tube improvement |
US11248674B2 (en) * | 2017-08-24 | 2022-02-15 | Ressorts Liberte Inc. | Coil spring and method of fabrication thereof |
US20220319792A1 (en) * | 2019-07-24 | 2022-10-06 | Dexerials Corporation | Protection element |
Also Published As
Publication number | Publication date |
---|---|
CN1682332A (en) | 2005-10-12 |
US7439844B2 (en) | 2008-10-21 |
AU2003242356A1 (en) | 2004-04-30 |
JPWO2004025679A1 (en) | 2006-01-12 |
WO2004025679A1 (en) | 2004-03-25 |
JP4342443B2 (en) | 2009-10-14 |
CN100367432C (en) | 2008-02-06 |
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